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  1. Ken McNeill

    Severe Motor Chattering Problem?

    I still have yet to resolve my chattering issue. I’m appealing to those of you who have been extremely helpful thus far (thank you again). I ordered a new motor and new motor controller from MacMotor. I connected the throttle directly to the MC rather than using the Pass-Thru on my CAV3...
  2. Ken McNeill

    Severe Motor Chattering Problem?

    I opened my original drawing file. I must have noticed my error the next morning and made the correction. I’m gonna celebrate with a margarita. 😎🌴 Here’s the corrected one.
  3. Ken McNeill

    Severe Motor Chattering Problem?

    Okay.. in my defense, by the time I got to the 4th diagram it was ‘margarita time’. I thought the colors balanced well there. 🤣🌴
  4. Ken McNeill

    Severe Motor Chattering Problem?

    Exactly. That’s what I was thinking. 🤣
  5. Ken McNeill

    Severe Motor Chattering Problem?

    I drew this a couple years ago for reference. I had been working with EM3ev at the time and can’t specifically remember why I drew it that way. When I looked t it yesterday, it just didn’t look right?
  6. Ken McNeill

    Severe Motor Chattering Problem?

    Brand new motor controller, new throttle & cable, brand new motor. Connected new throttle direct to motor controller. New motor controller to new motor.
  7. Ken McNeill

    Severe Motor Chattering Problem?

    All of your posts have been tremendously educational. I thought I knew e-bike operation well, but this has been enlightening. Thank you for that! 😎🌴 I never thought of the CA as just modulating throttle signal. Are wattage and current just calculated? How are they limited? There is a screen...
  8. Ken McNeill

    Severe Motor Chattering Problem?

    Well, I balanced the cell group and reinstalled the same battery. Connected BMS app and all groups balanced. Worked for a minute or two while I was attempting to put a load on the bike.. then the BMS lights on the outside of the pack went out. Now I got nothing. 🫤
  9. Ken McNeill

    Severe Motor Chattering Problem?

    Thanks to all of you for your time and thoughts. It is truly appreciated. 🤙 BTW, I have a 3 position switch that is programmed for 20A, 30A, and 40A. Problem occurs regardless of switch position.
  10. Ken McNeill

    Severe Motor Chattering Problem?

    This makes a lot of sense And you’ve got me re-thinking this. The battery would shut everything down, not just drop current flow. The power to the CA is supplied by the controller (6 pin connector). I thought maybe it was a data connection, but on second thought I don’t suppose it has to be. The...
  11. Ken McNeill

    Severe Motor Chattering Problem?

    I am seeing the current stutter on both. After 6-7 stutters, power shuts down and I hear a hum for a second or two. Once I’m riding on level ground, and apply throttle it works until amps hit 2-3A. Turn uphill under load, and there is not near enough power and shut stutter and shutdown with hum...
  12. Ken McNeill

    Severe Motor Chattering Problem?

    Wouldn’t the CAV3 be reflecting what voltage is at the controller (through its data connection)? I confirmed BMS voltage to CAV3 voltage. Identical. I’m thinking the smart BMS is stuttering power output as one cell group drops below a safety threshold. An LVC cutoff. I’m going to balance that...
  13. Ken McNeill

    Severe Motor Chattering Problem?

    Very likely. I plan to individually re-charge the cell group to balance the battery. We’ll see how it goes.
  14. Ken McNeill

    Severe Motor Chattering Problem?

    Just an update on my efforts to identify the issue. I finally received and installed a new motor controller which now tests good with the tester. I still had bad chattering under load, so I installed a new motor. As a tour operator, I try to keep replacement parts on the shelf. Same issue...
  15. Ken McNeill

    Severe Motor Chattering Problem?

    Does anyone have any specific or typical motor controller schematic diagrams?
  16. Ken McNeill

    Severe Motor Chattering Problem?

    I’m saving them all for a rainy day project. It’ll be fun and won’t impact my business! 😎🌴
  17. Ken McNeill

    Severe Motor Chattering Problem?

    I popped off one end to take a peek. Caps looked normal and there was absolutely zero electrical smell. Like new. My e-bikes are run at 8-12 mph on level ground. Motors barely get warm, let alone the motor controller. I don’t think high heat is the root cause. I think it’s some sort of failure...
  18. Ken McNeill

    Severe Motor Chattering Problem?

    Great information! I will pull it apart tomorrow and visually inspect tomorrow. My VOM is on the higher end so I believe it will test caps in that range. I do think I found a source for replacement controllers, but I like better understanding what is happening, and why. Thank you!
  19. Ken McNeill

    Severe Motor Chattering Problem?

    I did perform some resistance tests between batt-in +/- and FET output phase wires. No shorts. Motors run fine once spinning, but chatter under load. Found many Controller Tester videos online indicating if the light doesn’t continually rotate, controller is bad. Don’t have a ton of knowledge on...
  20. Ken McNeill

    Severe Motor Chattering Problem?

    They are never exposed to water and are in an enclosed housing.
  21. Ken McNeill

    Severe Motor Chattering Problem?

    I may try that as MAC Motor wants $199 each + expensive shipping from China. I paid $90 each from EM3ev. Does anyone know of a more local USA source, or a better replacement? I really don’t need 40A as 25A would do.
  22. Ken McNeill

    Severe Motor Chattering Problem?

    I’ll see what I can find on that tune and compare to my configuration. Thanks a bunch.
  23. Ken McNeill

    Severe Motor Chattering Problem?

    Thanks! I concur with everything you said. Nothing has changed with CAV3 FW or programming. Just a slow degradation resulting in noise and then chattering, resulting in quick clutch failure from the hammering effect. Batteries are in great shape. The MC is mounted in an unventilated housing...
  24. Ken McNeill

    Severe Motor Chattering Problem?

    I’ve used the ramping quite extensively 1vps-3vps, based on rider skills. I hope that didn’t cause the issues. The bikes were pretty ‘hot’ when I first built them, so I toned them down a bit through ramping. I’ll have to look to those articles? They are all set at 3vps currently. These are the...
  25. Ken McNeill

    Severe Motor Chattering Problem?

    I haven’t tried other controllers, but when they were new they worked great. Slowly, over time the motors have been getting noisier. I have seven bikes and 2-3 are starting to have similar issues. I figured the MC’s would either work.. or not work. Not some where degraded in between?
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