SPTBMDJ TF100 36V/48V Electric Scooter Brushless Motor Controller Instruction Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of your SPTBMDJ TF100 36V/48V Electric Scooter Brushless Motor Controller. Designed for Sealup electric scooters, this controller ensures efficient and reliable performance. Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Safety Instructions

• Always disconnect the scooter's battery before performing any installation, maintenance, or repair work on the controller or associated components.
• Ensure all connections are secure and properly insulated to prevent short circuits and electrical hazards.
• Do not expose the controller to water or excessive moisture. The unit is not waterproof.
• Handle the controller with care to avoid physical damage.
• If you are unsure about any installation steps, consult a qualified technician.
• Verify that the controller's voltage and current ratings match your scooter's motor and battery specifications. This controller supports 36V and 48V systems.

3. Product Overview

3.1. Description

The SPTBMDJ TF100 is a high-quality brushless motor controller designed as a replacement part for Sealup electric scooters. It is available in 36V and 48V configurations, with current ratings such as 16A and 20A. This controller is built for durability and long service life, featuring exquisite workmanship and simple operation.

3.2. Key Features

• Voltage Compatibility: Supports both 36V and 48V electric scooter systems.
• Brushless Motor Control: Optimized for efficient control of brushless DC motors.
• Durable Construction: Made from high-quality materials for extended reliability.
• Easy Installation: Designed for straightforward replacement of existing controllers.
• Display Compatibility: Available in two types (A and B) to match different display plug configurations (5-pin for Type A, 6-pin for Type B).

3.3. Components and Labeling

Image 1: Front view of the SPTBMDJ TF100 controller, displaying its label with specifications such as "VOLTAGE: DC36V", "CURRENT: 16A", "BRAKES: LOW LEVEL", "BOOSTER: 6 start strength choose", and "SPEED SET: 1-4.2V DUAL MODE". This label provides critical operational parameters.

Image 2: Top-down view of the SPTBMDJ TF100 controller, showing the array of multi-colored wires and connectors extending from one end. These wires are for connecting to the motor, battery, display, throttle, and brake systems of the electric scooter.

Image 3: Another perspective of the SPTBMDJ TF100 controller, highlighting the organized arrangement of its wiring harness. This view helps in identifying the various connection points for installation.

The controller features multiple wire harnesses for connecting to various scooter components. It is crucial to identify each wire's function before connection. The label on the controller (as seen in Image 1) indicates key parameters such as voltage, current, brake type, booster settings, and speed control mode.

4. Setup and Installation

Before beginning installation, ensure the scooter's power is completely off and the battery is disconnected. Refer to your scooter's original wiring diagram if available.

4.1. Identifying Controller Type

The SPTBMDJ TF100 controller comes in two types based on display compatibility:

• Type A: Matches 5-pin plug displays.
• Type B: Matches 6-pin plug displays.

Verify the plug type of your scooter's display before connecting the controller.

4.2. Wiring Connections (General Guide)

The controller features various color-coded wires for specific functions. While exact color codes may vary slightly, the general connections are as follows:

1. Power Wires (Thick Red/Black): Connect the thick red wire to the positive (+) terminal of the battery and the thick black wire to the negative (-) terminal. Ensure correct polarity.
2. Motor Wires (Thick Yellow/Green/Blue): These are the phase wires. Connect them to the corresponding phase wires of the brushless motor.
3. Hall Sensor Wires (Thin Red/Black/Yellow/Green/Blue): These wires provide feedback from the motor's Hall sensors. Connect them to the motor's Hall sensor connector.
4. Display/Throttle Wires: Connect the appropriate wires to your scooter's display unit and throttle. Pay close attention to the 5-pin or 6-pin display plug type.
5. Brake Lever Wires: Connect to the brake levers. The controller supports low-level brake signals.
6. Other Wires: Additional wires may be present for functions like cruise control, speed limit, or anti-theft. Refer to your scooter's specific wiring diagram for these connections.

After making all connections, double-check for any loose wires or incorrect polarity before reconnecting the battery and testing the scooter.

5. Operating Instructions

Once the controller is correctly installed and connected, the scooter can be operated as usual. The controller manages power delivery to the motor based on throttle input and other sensor data.

• Power On/Off: Use the scooter's main power switch or display unit to turn the system on or off.
• Throttle Control: The controller interprets the throttle signal (typically 1-4.2V for speed setting) to adjust motor speed.
• Brake Function: When the brake levers are engaged, the controller will cut power to the motor, and if applicable, activate regenerative braking or electronic braking. This controller supports low-level brake signals.
• Booster Function: The controller features a "BOOSTER: 6 start strength choose" setting, which allows adjustment of the initial acceleration strength. Consult your scooter's display or manual for how to access and modify this setting if available.
• Dual Mode Operation: The "SPEED SET: 1-4.2V DUAL MODE" indicates the controller can operate in a dual mode, likely referring to both Hall sensor and sensorless operation, or different speed profiles.

6. Maintenance

Proper maintenance ensures the longevity and optimal performance of your controller.

• Keep Dry: Protect the controller from water and moisture. If it gets wet, disconnect power immediately and allow it to dry completely before re-applying power.
• Cleanliness: Periodically clean the exterior of the controller to prevent dust and debris buildup, which can affect heat dissipation. Use a dry, soft cloth.
• Inspect Connections: Regularly check all wire connections for tightness and signs of wear or corrosion. Secure any loose connections.
• Avoid Overheating: Ensure the controller is mounted in a location with adequate airflow to prevent overheating during prolonged use.

7. Troubleshooting

If you encounter issues with your scooter after installing the controller, consider the following troubleshooting steps:

• No Power to Scooter:
  • Check battery charge level.
  • Verify all power connections (battery to controller) are secure and correct polarity.
  • Inspect the main power switch or ignition for faults.
• Motor Not Responding to Throttle:
  • Ensure throttle wires are correctly connected and not damaged.
  • Check motor phase wires and Hall sensor wires for proper connection.
  • Verify the display unit is functioning and communicating with the controller (especially for A/B type compatibility).
• Erratic Motor Behavior:
  • Re-check all motor and Hall sensor wire connections.
  • Ensure no wires are short-circuiting or making intermittent contact.
• Brakes Not Functioning:
  • Inspect brake lever sensor wires and connections.
  • Ensure the brake levers are properly adjusted.

If problems persist after troubleshooting, it is recommended to seek assistance from a qualified electric scooter technician or contact the seller for support.

8. Specifications

9. Warranty and Support

For warranty information or technical support regarding your SPTBMDJ TF100 controller, please refer to the purchase documentation or contact the seller directly. Keep your proof of purchase for any warranty claims.