999zip999 wrote:Is I was scared of hooking up a wrong connection and blowing this rebuild controller. So Neilp what is the best way to protect a controller when triing out different combo's.
I make my phase connections using thin wires with alligator clips along with the positive or negative power wire for the controller....easy to swap and can't support enough current to hurt anything. Just make sure the ends at the controller and motor wires can't short. Once the small pulses reveal what seems to be correct combination, then I ease on the throttle to WOT to verify. I do that slowly so I don't push high current through those small wires. If I get a valid reverse, then I swap 2, any 2, only 2 hall wires, and go back to swapping the phases for the correct combo. Once running smooth and proper direction, I put the multimeter in line with the battery lead on the alligator clip to verify low current as further proof of right combo, and to get the no load current so I can calibrate the CA at the same time.
It's really a quite simple process. People over complicate it with talk about 36 combos, and then people start swapping both. Once it sinks in that every phase combination has 1 valid hall combo, and every hall combo has 1 valid phase combo, then it becomes obvious that you don't change both. What you don't know is whether that valid one is forward or reverse (there are 3 of each). Be careful of false positives, which spin the wheel but sound a bit rough on startup. Every false positive I have seen has been the opposite direction for the set you are keeping static (halls using my method), so if a combo spins it backward but sounded a bit rough, that's a good sign.
Also be careful of bad connections, which make a good combo impossible to find. The end hall spades can slide to the side instead of into the connector too. I like to slide the hall connector in and out a few times when making the connection to ensure a good contact.
Once you get that right combo, undo the alligator clips one at a time, and make the solid connection before going to the next, so you don't lose track. Also, do yourself a favor and pick up some yellow, blue, green, red, and black electrical tape. Use it to color code your phase wire ends on the controller side to match the motor phase wires to avoid going through the process again at a future date with the same motor and controller.
Also note that the most common difference from matching colors is a swap of the yellow and blue phase wires, so try that first if color on color doesn't work. Be systematic. If the yellow and blue swap didn't work either, then you've already tried both combos of green on green, so next try the 2 combos of green on yellow, and then the 2 of green on blue. That's 6, so you have it by now, or at least a good reverse. See above for how to handle reverse.
Whatever you do don't get frustrated and give it WOT. My only burned motor, a little Bafang, resulted from doing that....burned the controller too. My next wiring attempt was after I went through the logic exercise and realized just how easy it is. My wires could all be black and I'd find the right wiring just as quickly. On a dare I could eaily do it blindfolded, though I'd have to go slower, preferably with a helper to watch for shorts.