SUNGOOYUE DC Motor Controller User Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your SUNGOOYUE DC Motor Controller. This controller is designed for electric bikes, supporting universal 36V and 48V lithium battery systems and compatible with 250-350W motors. Please read this manual thoroughly before use to ensure proper function and safety.

2. Product Features

• Universal Voltage Compatibility: Supports both 36V and 48V lithium battery systems.
• High Efficiency: Optimized for 250W to 350W electric bike motors with a maximum current of 17A.
• Enhanced Heat Dissipation: Features a grooved aluminum alloy cover designed to prevent thermal overload and ensure efficient cooling.
• Durable Construction: Lightweight yet robust aluminum alloy casing provides longevity and resistance to deformation and wear.
• Stable Connections: Equipped with standard wires and interfaces for reliable and secure electrical connections.
• Compact Design: Space-saving structure allows for easy installation in various electric bike configurations.

Image: The SUNGOOYUE DC Motor Controller, illustrating its compact design and highlighting key features such as 36V/48V compatibility, 250-350W motor support, grooved heat dissipation, and durable aluminum alloy construction.

3. Specifications

4. Package Contents

The package includes the following items:

• 1 x DC Motor Controller
• 1 x User Manual (this document)

5. Safety Information

• Always disconnect power before installation or maintenance.
• Ensure all connections are secure and correctly polarized to prevent damage to the controller or other components.
• This controller is designed for electric bikes. Do not use it for unintended applications.
• Keep the controller away from water and extreme temperatures.
• Professional installation is recommended if you are unfamiliar with electrical systems.
• Ensure the motor and battery specifications are compatible with the controller's voltage and current ratings.

6. Setup and Installation

Follow these steps for proper installation of the DC Motor Controller. Refer to the wiring diagram for connection details.

1. Mounting: Securely mount the controller in a location that is protected from physical damage and moisture, allowing for adequate airflow for heat dissipation.
2. Battery Connection (2-pin): Connect the battery wires to the controller's 2-pin battery connector. Ensure correct polarity (red to positive, black to negative).
3. Motor Phase Line Connection (3-pin): Connect the three phase wires from your motor to the controller's 3-pin phase line connector.
4. Motor Hall Line Connection (6-pin): Connect the Hall sensor wires from your motor to the controller's 6-pin Hall line connector.
5. Throttle Connection (3-pin): Connect the throttle unit to the controller's 3-pin throttle connector.
6. Display Connection (5-pin): If your electric bike has a display unit, connect it to the controller's 5-pin display connector.
7. E-Brake Connection (2-pin): Connect the E-brake levers to the controller's 2-pin E-brake connectors.
8. Light Connection (2-pin): If applicable, connect your bike's lights to the controller's 2-pin light connector.
9. PAS (Pedal Assist System) Connection (3-pin): Connect the PAS sensor to the controller's 3-pin PAS connector.
10. Final Check: Double-check all connections to ensure they are firm and correctly aligned before applying power.

Image: Detailed wiring diagram for the SUNGOOYUE DC Motor Controller, showing labeled connectors for PAS, Phase line, Hall line, E-brake, Throttle, Light, Display, and Battery. Each connector type and pin count is clearly indicated.

Image: The SUNGOOYUE DC Motor Controller with its various colored wires and connectors extending, providing a visual reference for the physical connections.

Note: This controller must be used with an instrument that supports the Model 2 communication protocol.

7. Operating Instructions

Once the controller is correctly installed and all connections are secure, you can begin operating your electric bike.

1. Power On: Turn on your electric bike's battery and display (if applicable). The controller will initialize.
2. Throttle Control: Use the throttle to control the motor's speed. Apply gentle pressure for smooth acceleration.
3. Pedal Assist: Engage the pedal assist system (PAS) by pedaling. The motor will provide assistance based on your pedaling input and the selected assist level (if available on your display).
4. Braking: The E-brake function will cut power to the motor when the brake levers are engaged, ensuring safe stopping.
5. Power Off: Always turn off the battery and display when you are finished riding to conserve power and prevent accidental activation.

8. Maintenance

Regular maintenance helps ensure the longevity and optimal performance of your DC Motor Controller.

• Keep Clean: Periodically clean the controller's exterior to prevent dust and dirt buildup, which can hinder heat dissipation. Use a dry, soft cloth.
• Check Connections: Regularly inspect all wire connections for looseness, corrosion, or damage. Tighten any loose connections and replace damaged wires immediately.
• Avoid Water Exposure: While the aluminum casing offers some protection, avoid direct exposure to heavy rain or submersion in water.
• Temperature Management: Ensure the controller is not covered or obstructed during operation to allow for proper heat dissipation.
• Software Updates: If applicable, consult your electric bike manufacturer for any recommended firmware updates for the controller.

9. Troubleshooting

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

If the problem persists after attempting these solutions, please contact customer support.

10. Warranty and Support

For warranty information or technical support, please refer to the product packaging or contact SUNGOOYUE customer service through your retailer or the official brand website. Keep your purchase receipt for warranty claims.