1. Introdução
This manual provides essential information for the safe and effective installation, operation, and maintenance of your Headerbs Electric Scooter Motor Controller. This controller is designed for electric scooters and tricycles, compatible with 48V, 60V, and 64V battery systems, and 1000W to 1500W brushless motors. Please read this manual thoroughly before use to ensure proper function and longevity of the product.
Figure 1.1: Headerbs Motor Controller and Compatible Vehicles.
2. Informações de segurança
- Always disconnect the power source before installing, maintaining, or troubleshooting the controller.
- Ensure all connections are secure and correctly wired to prevent short circuits or damage.
- Avoid exposing the controller to water, excessive moisture, or extreme temperatures.
- Do not attempt to open or modify the controller casing, as this may void the warranty and pose safety risks.
- Installation should be performed by individuals with appropriate electrical knowledge.
3. Produto acabadoview
The Headerbs Electric Scooter Motor Controller is a 12-tube (dual-mode) brushless speed controller designed to enhance the performance of your electric vehicle. It offers smooth motor starts, improved climbing power, and reduced motor noise.
Figure 3.1: Headerbs Electric Scooter Motor Controller.
Principais características:
- Desempenho do motor aprimorado: Allows the drive motor to start more smoothly, providing a comfortable riding experience.
- Enhanced Climbing Power: Empowers your electric vehicle with greater climbing abilities, with quieter motor operation and reduced tire noise.
- Wide Motor Compatibility: Supports sine motors, motors, and no-Hall motors, catering to various electric configurations.
- 12-Tube Design: Ensures stable power supply, accurate motor phase line control, and precise speed adjustments.
Variações do produto:
Please note that the controller may be shipped in either a new or old model type. Both types offer the same functionality and performance specifications.
Figure 3.2: Comparison of New Type and Old Type Controller Models. Both models provide identical functionality.
4. Configuração e instalação
Careful wiring is crucial for the correct operation of the motor controller. Refer to the wiring diagram below and follow the instructions for each connection.
Figure 4.1: Wiring Diagram for Headerbs Motor Controller.
Conexões de fiação:
- Power (Red & Black): Connect the main red and black power lines from your battery to the corresponding power input on the controller. Ensure correct polarity.
- Motor Phase Lines: Connect the three motor phase lines (typically yellow, green, blue) from the controller to the motor.
- Hall Wire: If your motor has Hall sensors, connect the Hall sensor wires from the motor to the controller's Hall wire connector. The controller also supports no-Hall motors.
- Electric Door Lock: Connect the electric door lock wire to the ignition switch of your vehicle.
- Speed Control Handle: Connect the throttle (speed control handle) wires to the designated connector for speed input.
- Shift Three-speed Gear: Connect these lines to your vehicle's three-speed switch for speed mode selection.
- Low Level Brake & High Level Brake: Connect these to your vehicle's brake levers or sensors.
- Marcha à ré: Connect this wire if your vehicle supports a reverse function.
- Anti-theft Alarm Power & Signal: Connect these to your anti-theft alarm system for security features.
- Multiple Data Meter / General Instrument Line: Connect to your vehicle's display or instrument panel for data output.
- Learning Wire: This wire is used for intelligent recognition and self-learning of motor parameters. Connect these two wires together briefly during initial setup to allow the controller to learn your motor's characteristics, then disconnect them.
Importante: This controller is suitable for monitors without communication protocol. Ensure your display unit is compatible.
5. Instruções de operação
- Ligar: Turn the electric door lock to the "ON" position. The controller will initialize.
- Controle de velocidade: Use the speed control handle (throttle) to accelerate. The controller provides smooth acceleration.
- Modos de velocidade: If connected, use the three-speed gear switch to select between different speed modes (e.g., low, medium, high).
- Frenagem: Apply the brake levers. The controller will cut power to the motor based on the brake signal (low or high level).
- Função reversa: If connected, activate the reverse switch to engage the reverse gear.
- Anti-roubo: If an anti-theft alarm is connected, activate it as per your alarm system's instructions.
6. Manutenção
- Inspecione regularmente todas as conexões da fiação para verificar se estão bem apertadas e se apresentam sinais de desgaste ou corrosão.
- Keep the controller clean and free from dust, dirt, and debris. Use a dry cloth for cleaning.
- Garanta ventilação adequada ao redor do controlador para evitar superaquecimento.
- Não use produtos químicos ou solventes agressivos para limpeza.
7. Solução De Problemas
| Problema | Possível causa | Solução |
|---|---|---|
| Motor does not start or runs intermittently. | Loose power connection, faulty throttle, motor phase line issue, Hall sensor issue (if applicable). | Check all power and motor phase connections. Inspect throttle wiring. If using a Hall motor, check Hall sensor connections. Perform learning wire procedure again. |
| Controller overheats. | Insufficient ventilation, overloaded motor, short circuit. | Ensure proper airflow around the controller. Verify motor power consumption is within controller limits. Check for any short circuits in wiring. |
| Incorrect speed or erratic acceleration. | Faulty throttle, incorrect three-speed gear setting, learning wire not properly used. | Test the throttle. Check the three-speed gear switch connections. Ensure the learning wire procedure was completed correctly during setup. |
| Brakes not functioning correctly. | Brake lever switch issue, incorrect brake line connection. | Inspect brake lever switches and their wiring to the controller's low/high brake lines. |
| Display/Instrument panel not showing data. | Incorrect instrument line connection, incompatible display. | Verify the general instrument line connection. Confirm your display unit is compatible with a controller that does not use a communication protocol. |
8. Especificações
| Tipo de item | Controlador de motor |
| Material | Metal |
| Volumetage Compatibilidade | 48V, 60V, 64V |
| Faixa de potência | 1000W - 1500W |
| Limite de corrente | 26A - 30A |
| Dimensões (C x L x A) | 17.7 x 8.4 x 4.1 cm (7 x 3.3 x 1.6 polegadas) |
| Peso | 460g (1.16 libras) |
| Veículos Aplicáveis | Electric Car, Tricycle (with max power 1000W) |
| Número do modelo | 72V |
Figure 8.1: Controller Dimensions.
9. Suporte e garantia
Headerbs is committed to customer satisfaction. If you encounter any issues or have questions regarding your motor controller, please contact our customer support team. While specific warranty details are not provided in this manual, we strive to offer satisfactory solutions for any product-related concerns.
For assistance, please refer to the contact information provided with your purchase or visit the official Headerbs store page.
