Fechters Hall tester board -> saves the Day

methods

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So I have been up for days working out the bugs with these new 18 Fet Infineon II controllers

http://endless-sphere.com/forums/viewtopic.php?f=2&t=10312

Instant_Start_18Fet_008.jpg

I went through all 36 possible combinations for the hall/phase 4 times
(yes, that's 144 tests - Twice each on two different motors)

No matter what I did I could not get a good combination
I checked each hall signal multiple times and they were good
I checked the +5 line and ground - good.

This is far from the fist motor-controller I have hooked up but I decided that perhaps I was missing something silly.
I went to the Technical Reference area and had another look at Fechters tips-

http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484&start=0

There is a nice circuit in there for visually testing out motors
Hall Sensor Tester.jpg

I made 2 modifications:
- I set it up for a rechargeable 4.8V battery (dropped the 470ohm resistor)
- I also set it up to either run in-line with the controller or independently

Hall_Tester_002.jpg

Plug in the battery, attach to motor, and the halls can be read

Hall_Tester_003.jpg

Detach battery, plug in controller, halls can be read in-line

I found something very interesting

When connected directly to the battery, the 9C motor I was using gave the following CODE

(-) means OFF

AB-
A--
A-C
--C
-BC
-B-

AB-
A--
A-C
--C
-BC
-B-

You can see that the LED's are walking from left to right like we would expect

Now... When I hooked up the Controller, GUESS WHAT I FOUND ?!?!

ABC
A--
ABC
-BC
ABC
A--

ABC
A--
ABC
-BC
ABC
A--

AH HA!

B and C are shorted together!
No amount of "simple testing" would have shown me that unless I was looking for it or writing down the patterns
This little 5 minute project just became the first tool in line when I have hall problems.

Some times we think we are too smart for our own good and we have to roll the clock back to the old school..... Led tester!

-methods

P.S. The 10x6 and 9x7 9C motors like to run on 88V :twisted:
I have a pair of them (front and rear)
 
i converted the 9 FET infineon to 72V and it ran like a bat outa hell at 86V.

what are you using for the input power resistors?

the 9FET model uses 53mA at idle, and it climbs to 62mA under load.

i used 530R and 540R for the 2 i converted, and set the LVC to 51 and 55V using 1k6R for the bypass resistor from R12 to ground.

i also added 3 100V1000uF caps to replace the 63V470uF originals.

http://www.endless-sphere.com/forums/viewtopic.php?f=2&t=10222
 
dnmun said:
what are you using for the input power resistors?

(3) 1.8K's in parallel.
This is for 70V - 105V range

-methods
 
rkosiorek said:
my version is a little overdesigned. Fechter benifited from my overdesign to make the simple one.

WOW :shock:
That is a little over designed :)
Looks good

-methods
 
Hey methods..

I had his problem too once

except i had happed inside the hub motor .. fortunatly no hall sensors where harmed

-steveo
 
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