1. Introduction
This manual provides essential information for the safe and effective installation, operation, and maintenance of your Generic 48V/60V/72V 1200W Brushless FOC Electric Vehicle Motor Controller. Please read this manual thoroughly before use to ensure proper function and to prevent damage to the product or injury.
The controller is designed for use with electric kick scooters and similar electric vehicles, providing efficient power management for brushless motors.
2. Safety Information
WARNING: Electrical components can be dangerous. Always disconnect power before installation or maintenance. Professional installation is recommended.
- Ensure the power source matches the controller's rated voltage (48V, 60V, or 72V).
- Do not attempt to open or modify the controller casing.
- Keep the controller away from water, moisture, and extreme temperatures.
- Verify all connections are secure and correctly polarized before applying power. Incorrect wiring can cause severe damage to the controller, motor, and battery.
- Wear appropriate personal protective equipment during installation.
3. Product Overview
The Generic Brushless FOC Electric Vehicle Motor Controller is a compact unit designed to manage the power delivery to a brushless motor. It features multiple wiring harnesses for various connections including power, motor phases, Hall sensors, throttle, brakes, and other auxiliary functions.
Package Contents:
- 1 x Generic 48V/60V/72V 1200W Brushless FOC Electric Vehicle Motor Controller
Visual Reference:
Figure 3.1: Top-down view of the Generic Brushless FOC Motor Controller. The main black casing houses the electronics, with a metal mounting plate visible underneath. Multiple color-coded wire harnesses extend from the sides, equipped with various connectors for integration into an electric vehicle system.
Figure 3.2: A detailed close-up view of the various wiring connections on the motor controller. Different colored wires terminate in distinct connectors, indicating their specific functions such as power input, motor phase connections, Hall sensor inputs, throttle, and brake signals. Some wires are bundled with spiral wrap for protection.
4. Specifications
| Feature | Specification |
|---|---|
| Rated Voltage | 48V / 60V / 72V (Auto-sensing) |
| Rated Power | 1200W |
| Main Material | Aluminum Alloy |
| Model Name | LJ2407101 |
| Color | Black |
| Included Components | Brushless FOC Motor Controller |
5. Setup and Installation
Proper installation is crucial for the performance and longevity of the motor controller. Refer to your electric vehicle's specific wiring diagram in conjunction with these general instructions.
General Wiring Connections:
- Power Input: Connect the main positive (+) and negative (-) wires from your battery to the corresponding power input terminals on the controller. Ensure correct polarity.
- Motor Phase Wires: Connect the three thick motor phase wires (typically green, blue, yellow) from your motor to the corresponding phase output wires on the controller.
- Hall Sensor Wires: Connect the thin Hall sensor wires (typically five wires: +5V, GND, and three signal wires) from your motor to the Hall sensor input on the controller. Match colors carefully.
- Throttle: Connect the throttle unit's wires (typically +5V, GND, and signal) to the throttle input on the controller.
- Brake Levers: Connect the brake lever wires to the brake input on the controller. Some controllers have separate high-level and low-level brake inputs.
- Ignition/Key Switch: If applicable, connect the ignition wire to the controller's ignition input.
- Other Auxiliary Connections: Connect any other accessories such as lights, display, or speed sensor according to their specific wiring diagrams and the controller's available ports.
After all connections are made, double-check them for security and correctness before applying power. Secure the controller in a location that is protected from physical damage, moisture, and allows for adequate ventilation.
6. Operating Instructions
Once the controller is correctly installed and all connections are verified:
- Power On: Turn on the main power switch or ignition key of your electric vehicle. The controller will typically perform a self-check.
- Throttle Operation: Gently twist the throttle to engage the motor. The motor speed will increase proportionally with the throttle input.
- Braking: Activating the brake levers will cut power to the motor and engage the vehicle's braking system.
- Voltage Compatibility: The controller is designed to automatically detect and operate with 48V, 60V, or 72V battery systems. Ensure your battery voltage is within this range.
Always operate your electric vehicle responsibly and in accordance with local laws and regulations.
7. Maintenance
The Generic Motor Controller is designed for durability, but regular checks can help ensure optimal performance and extend its lifespan.
- Keep Clean: Periodically clean the exterior of the controller to prevent dust and debris buildup, which can affect heat dissipation. Use a dry, soft cloth.
- Check Connections: Regularly inspect all wiring connections for tightness and signs of corrosion or wear. Loose connections can lead to intermittent power, overheating, or component failure.
- Environmental Protection: Ensure the controller remains protected from direct exposure to water, heavy rain, or extreme temperatures.
- Avoid Overloading: Do not exceed the rated power of the controller (1200W) or operate it with an incompatible motor, as this can lead to overheating and damage.
8. Troubleshooting
If you encounter issues with your motor controller, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor does not run | No power to controller; Loose connections; Faulty throttle; Faulty motor Hall sensors. | Check battery charge and connections; Inspect all wiring; Test throttle function; Check motor Hall sensor wires. |
| Motor runs intermittently | Loose wiring; Intermittent throttle signal; Overheating. | Secure all connections; Check throttle wiring; Allow controller to cool down and ensure proper ventilation. |
| Motor makes unusual noise | Incorrect motor phase wire connection; Damaged motor or controller. | Verify motor phase wire connections; Consult a professional for diagnosis. |
| Controller gets excessively hot | Overloading; Insufficient ventilation; Short circuit. | Reduce load; Ensure controller is in a well-ventilated area; Check for short circuits in wiring. |
If the problem persists after attempting these solutions, contact the seller for further assistance.
9. Warranty and Support
For information regarding the warranty period and terms for this Generic motor controller, please refer to the product listing or contact the seller directly. Warranty coverage typically addresses manufacturing defects.
For technical support, troubleshooting beyond this manual, or replacement parts, please contact the seller through the platform where the product was purchased. Provide your order number and a detailed description of the issue for efficient assistance.