Spark Motors TH-G Series User manual
TH-G
Series
Brushless
DC
Motor
Driver
User’s Manual
Applicable product model：
TH-G048DC200X-WHO TH-G048DC201X-WHO
TH-G048DC300X-WHO TH-G048DC301X-WHO
TH-G048DC400X-WHO TH-G048DC401X-WHO
TH-G048DC600-WHO TH-G048DC601-WHO
TH-G072DC300X-WHO TH-G072DC301X-WHO
TH-G072DC450X-WHO TH-G072DC451X-WHO
TH-G072DC600X-WHO TH-G072DC601X-WHO
TH-G072DC800X-WHO TH-G072DC801X-WHO
TH-G072DC100-WHO TH-G072DC101-WHO
TH-G072DC120E-WHO TH-G072DC121E-WHO
Contents
Chapter
One
Summar ...................................................
。
。。
。
Chapter
Two
Main
Features
and
Specifications
.........
。
。。
。
2.1
Basic
Functions......................................................................3
2.2
Features....................................................................................
5
2.3
Specifictions..........................................................................
6
2.4
Models........................................................................................
7
Chapter
Three
Installation
Method.....................................................8
3.1
Install
Controller................................................................8
3.2
Line
Connection....................................................................11
3.3
Inspect
Installing..............................................................15
Chapter
Four
Maintenance................................................................
16
4.1
Clearance................................................................................
16
4.2
Configuration........................................................................
17
Table
1:
LED
error
code............................................................
1
Contact
Us
.........................................................................................20
Chapter One Summary
This manual describes the characteristics of TH-G series e-bike controller
products, the knowledge of installation method and maintenance. Before
using the Changhzou Spark Motors controller, please read this manual in
detail, which will help you to install and use the Changhzou Spark Motors
controller correctly. If you have any problems with using, please contact
us at the last page of this document.
TH-G series programmable controller is Changhzou Spark Motors
company dedicated to an efficient, stable and easy to install the
electric vehicle controller design, suitable for electric bicycles,
electric motorcycles and electric scooter etc.. The series controller is
able to output a high starting current and supply tight battery current
limit. Therefore, it can work in a relatively small battery current
conditions, and can provide a good acceleration and climbing ability.
Changhzou Spark Motors controller uses high power MOSFET high
frequency design, the efficiency is up to 99%. Powerful intelligent
microprocessor provides a comprehensive and accurate control for the
Changhzou Spark Motors controller. The user can also connect the
computer and the controller through the connecting wires we provide,
to configure the controller, to guide the test and to obtain the diagnostic
information simply and quickly.
Chapter Two Main Features and Specifications
2.1 Basic Functions
(1) Fault detection and protection. It can identify faults via
LED
twinkling code.
(2) Battery voltage real-time monitoring. It will stop work when
battery voltage is higher or lower.
(3) Built in current detection and over current protection.
(4) The controller is equipped with temperature measurement
and protection functions. At low and high temperatures, the current is
cut to protect the controller and the battery. If the controller
temperature
is higher than 90 , the current will be a sharp decline. It
will
automatically cut off the output when it is up to 100 . At
low temperatures, the current typically begins to drop at 0 .
(5) At power-up, the voltage is constantly monitored by
the controller. If it is found that the voltage is too high, the
controller will immediately cut the current until the power generation
stops.
(6) The maximum speed can be configured half the maximum
forward speed.
(7) The controller can be configured by connecting to the serial port
of the computer and the software can be updated. The
controller configuration program runs on all versions of Windows.
(8) 5V sensor power supply.
(9) 3 switch inputs. Connect to GND for valid signal. The default is
the pedal safety switch input (to be configured via the customer
software), the brake switch input and the reversing switch input.
(10) Three 0-5V analog inputs. The default is the pedal analog
signal input, the brake analog signal input and the motor temperature
sensor analog signal input.
(11) The Boost switch can be configured. The controller will output
the maximum current, when the switch is turned on.
(12) The Economy switch can be configured. Limiting the
maximum drive current to the controller is half the normal
case, when the switch is turned on.
(13) The maximum current that can be configured half the
maximum forward current.
(14) Enhanced power generation brake function. The original ABS
brake technology, so that your brakes are more powerful
and smooth.
(15) 12V brake signal input can be configured.
(16) Motor over-temperature detection and protection (need to
use our designated semiconductor temperature sensor KTY84-130).
(17) 3-phase Hall position sensor input, open collector output
and the controller provides pull-up resistor.
(18) Controller power supply range is 8-30V optional.
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2.2 Features
(1) Designed for electric motorcycles and electric scooters
(2) Powerful and intelligent microprocessor
(3) High-speed low-loss synchronous rectification PWM modulation
(4) Strict current limit and torque control
(5) Limit the battery current function will not trigger the
battery current limit protection and extend battery life.
(6) Greater starting current can get a faster start-up speed
(7) Anti-electromagnetic interference and anti-vibration performance
(8) Fault indicator indicates a variety of failures for user-
friendly testing and maintenance
(9) With electronic switching function
(10) It has a battery protection function: when the battery voltage is
low, the alarm will be timely and the current attenuation, low output
to stop the protection of the battery
(11) Beautiful and fast heat dissipation of aluminum with a heat spur
shell
(12) With over-temperature protection: when the temperature is too
high or too low will automatically current attenuation to protect the
controller and battery
(13) Compatible with 60 degrees or 120 degrees Hall position sensor
(14) Support any poles of brushless motor.
(15) Up to 40000 electric RPM. (electric RPM = mechanical speed *
motor pole pairs)
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(16) The brake switch is used to control the regenerative braking
(17) 0-5V brake signal is used to control regenerative braking
(18) High pedal protection: The pedal signal is detected when
the key is turned on, and is not output if a valid signal is present
(19) Three power generation modes: brake switch power generation,
release pedal power generation and 0-5V analog signal
power generation
(20) Current multiplication: Small battery current can get larger
motor output current
(21) Easy to install: use a 3-wire pedal potentiometer to work
2.3 Specifications
(1) Working frequency: 16.6KHz
(2) Standby current: less than 0.5A
(3) 5V sensor supply current: 40mA
(4) Supply voltage: 72V and 18V~72V
(5) Supply current: 150mA
(6) Working voltage: 18V to 1.25* nominal value
(7) Standard throttle input: 0-5V(Three wire resistance type ),
1-4V(HALL type)
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(8) Brake analog signal and throttle signal input: 0-5V. Using three wire
resistance type pedal to produce 0-5V signal
(9) Full power operating temperature range: 0~50(Controller shell
temperature)
(10) Working temperature range: -30-90,100 shutdown
(controller shell temperature)
(11)
Peak phase current, 10s: 50-120A(according to the model)
(12) Continuous phase current: 5-50A
(according to the model)
(13) Maximum battery current: adjustable.
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Chapter
Three
Installation
Method
3.1
Install
Controller
The
installation
position
of
the
controller
can
be
arbitrary,
but the
controller
should
be
kept
clean
and
dry.
If
you
can't
find
a clean
installation
position,
you
should
add
a
cover
to
prevent
it from
water
and
other
contaminants.
In
order
to
ensure
full
power
output,
the
controller
should
use the
four
screws
in
a
clean
and
flat
metal
surface,
the
controller and
bottom
plate
fixed
in
close
contact
with
sufficient
coolin thermal
rease
fillin
su estions.
Shell
outline
and
mountin
holes
are
shown
in
Fi ure
1
、
2
：
Attention:
Out
of
control:In
some
cases,
the
vehicle
may
be
out
of
control,
so
the
vehicle
should
be set
up
before
the
operation
of
the
electric
vehicle
control
circuit.
High
current
attention
：
Electric
vehicle
batteries
can
provide
a
very
high
current,
in
the
installation
of
electric
vehicles
before
the
control
circuit
must
be
disconnected
from
the battery
circuit.
With
insulation
tools
to
prevent
the
occurrence
of
short
circuit.
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Height:
62mm
Figure
1:TH-G
mounting
hole
size
(Unit:mm)
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Height:
62MM
Figure
2:TH-G
mounting
hole
size
(Unit:MM)
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3.2
Line
Connection
Five
metal
strips
and
a
rugged
connector(J2)
provide
the
connection
environment
for
battery,
motor
and
controller
signals.
As
shown
in
Feature
3:
Figure
3: Brushless motor controller front panel
B
+
: Battery positive
B
-
: Battery negative
A: Output U/1/A phase, connect motor with thick yellow
line B: Output V/2/B phase, connect motor with thick green
line C: Output W/3/C phase, connect motor with thick blue
line
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J2
Pin
definition:
1. PWR: Controller power supply (input)
2. RTN: Signal return, or power supply return
3. RTN: Signal return
4. 12V high-level brake and motor temperature input
5. Throttle analog input, 0-5V
6. Brake analog input, 0-5V
7. 5V: 5V supply output. <40mA
8. Throttle switch input
9. Reversing switch input
10. Brake switch input
11. Hall phase
12. Hall phase B
13. Hall phase A
14. RTN: Signal
return
Note:
1. All RTN and GND pins are internally connected, but isolated from B-.
2. Switch to ground is active. Open switch is inactive.
Caution: Make sure all connections are correct before apply power. Otherwise it
may damage the controller! Please securely wire B- before applying power. It's
preferred to place contactor or breaker on B+. Please place pre-charge resistor
on any breaker! It can cause damage without it
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Figure
5: TH-G controller standard wiring.
3.3 Communication Port
Figure 6: RS232 Interface
A RS232 port is provided to communicate with host computer for
calibration and configuration.
3.4 Installation Check List
Before operating the vehicle, complete the following checkout procedures.
Use LED code as a reference as listed in Table 1.
Caution:
• Put the vehicle up on blocks to get the drive wheels off the ground before
beginning these tests.
• Do not allow anyone to stand directly in front of or behind the vehicle during
the checkout.
• Make sure the PWR switch and the brake is off
• Use well-insulated tools.
1.Make sure the wire is connected correctly
2.Turn the PWR switch on. The Green LED stay on steadily and
Red LED turns off when the controller operates normally. If this
does not happen, check continuity of the PWR and return.
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3.The fault code will be detected automatically at restart.
4.With the brake switch open, select a direction and operate the throttle.
The motor should spin in the selected direction. Verify wiring or voltage
and the fuse if it does not. The motor should run faster with increasing
throttle. If not, refer to the Table 1 LED code, and correct the fault
as determined by the fault code.
5.Take the vehicle off the blocks and drive it in a clear area. It
should have smooth acceleration and good power.
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Chapter
4
Maintenance
There are no user-serviceable parts inside the controllers. Do not attempt
to open the controller. Or will void warranty. However, cleaning the
controller exterior periodically should be necessary.
The controller is inherently a high power device. When working with any
battery powered vehicle, proper safety precautions should be taken. These
include, but are not limited to, proper training, wearing eye
protection, avoiding loose clothing and jewelry, and using insulated tools.
4.1
Cleaning
Although the controller requires virtually no maintenance after properly
installation, the following minor maintenance is recommended in certain
applications.
• Remove power by disconnecting the battery, starting with battery
positive.
• Discharge the capacitors in the controller by connecting a load (such as a
contactor coil, resistor or a horn) across the controller’s B+ and B-
terminals.
• Remove any dirt or corrosion from the bus bar area. The
controller should be wiped with a moist rag. Be sure it is dry before
reconnecting the battery.
•
Make sure the connections to the bus bars are tight. Use two wrenches
for this task in order to avoid stressing the bus bars; the wrenches should
be well insulated.
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4.2 Configuration
You can configure the controller with a host computer through either an
RS232 or USB port.
Disconnect motor wiring from controller.
Do not connect B+, throttle and so on. The controller may display fault
code in some conditions, but it doesn't affect programming or
configuration.
Use straight through RS232 cable or USB converter provided
by
Changhzou Spark Motors to connect to a host computer. Provide >+18V
to PWR
（
for a 24V controller, provide >+8V
）
. Wire power supply
return(supply negative) to any RTN pin.
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1,3
* ***
Low voltage erro
r
1. The controller will clear after 5 seconds if
battery volts return to normal.
2. Check battery volts & recharge if required.
1,4
* ****
Over temperature warning
1. Controller case temperature is above 90*C.
Current will be limited. Reduce Controller
loading or switch off until controller cools
Down.
2.Clean or Improve heat sink or Fan.
2,1 ** * Motor did not start Motor did not reach 25 electrical RPM within
2 Second of start-up. hall sensor or phase
wiring problem.
2,2 ** ** Internal volts fault 1.Measure That B+ & PWR are correct when
measure to B- or RTN.
2. There may be excessive load on the +5V
Supply caused by too low a value of regen or
throttle potentiometers or incorrect wiring.
3.controller is damaged.
2,3 ** *** Over Temperature The controller temperature has exceeded
100*C. the Controller will be Stopped bot Will
Restart when temperature falls below 80*C.
2,4 ** **** Throttle error at power-up Throttle signal is higher than the preset dead
Zone" at Power On. Fault clears when Throttle
is released.
3,1 *** * Frequent reset May be caused by over-voltage, bad Motor
intermittent earthing problem, bad wiring, etc.
3,2 *** ** Internal reset May be caused by some transient fault
condition like a temporary over-current,
momentarily high or low battery voltage. This
can happen during normal operation.
3,3
*** ***
Hall throttle is open or
short-circuit
When the throttle is repaired, a restart will
clear the fault.
3,4
*** ****
Non
-
zero throttle on
direction change
Controller wont allow a direction change
unless the throttle or speed is at Zero. Fault
clears when throttle is Released.
4,1
**** *
Regen or start
-
up over
-
voltage
Motor Drive is disable if an over
-
voltage is
detected at start-up or during regen. The
voltage threshold detection level is set during
configuration.
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4,2
**** **
Hall sensor error
1. incorrect or loose wiring or a
damaged Hall sensor.
2. Also be caused by incorrect hall
angle configuration (60 degree or
120 degree).
4,3 **** *** Motor over-
temperature
Motor temperature has exceeded the
configured maximum. the Controller
will Shut Down until the motor
temperature.
4,4 **** **** Motor locked rotor When in locked rotor condition, the
max output phase current of the
motor will be limited to 90% of
previous current. once this problem
disappears, the fault will clear and
the max output phase current will
return to normal
The Red LED flashes once at power on as a confidence check and then
normal stays Off. "1, 2" means the Red flashes once and after a second
pause, flashes twice. The pause time between multiple flash code groups is
two seconds.
Contacts us:
SPARK MOTORS PVT. LTD.
Website: www.sparkmotors.in
E-mail: Sparkeaa@gmail.com / amit@sparkmotors.in
Tel: (022-27781125)
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This manual suits for next models
20
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