Crystalyte 72Volt 50A 18MOSFET Controller Issue - axle SNAPP

[dachopper]

Hey guys,

I'm looking for some help on connecting this controller to my H4060

Does anyone know which plug from this controller is supposed to plug into an E-brake. I cannot find any references anywhere - and of the plugs that are left over ( a 2 pin female, that also has a small loop wire that is attached to the end - but not pluged in, which would just loop the 2 plug to itself- is this some kind of reset?, a 3 pin male and 3 pin female, and 4 pin male ) I have no Idea what they are meant to be connected to - I already have the throttle, engine, and APM system attached.

Also I found that the first time I plugged this thing in, the motor behaved erratically, Ie initially it spun backwards, then I turned it off / on and it didn't spin at all ( It was trying to do something but nothing happend ) Then the third time I unplugged the 2 wires going to the motor, replugged them in, and It has worked flawlessly ever since.

Same motor that I've done 30 or so miles on over 4 - 5 rides, I plugged into a new controller that was the same type as my other one. Firstly got wheel spinning backwards like before, then unplugged, replugged in, got the wheel shuddering fwd and backwards, I disconnect / reconnect the wires, and bang - the on / off switch has internally shorted and doesn't actually turn off any more.

So it appears to me..... that the Controllers go through some wierd phase when you first get them to figure out how to drive the motor..... It definitely is not the motor because it was running flawlessly for weeks up to the point of changing the controller over. Any ideas on what is happening ?

Nick

 

[izeman]

a picture says more than 1000 words ....

 

[dachopper]

Never mind - I just succeeded in snapping the axle in half where the phase wired enter the axle dugout. Yay for me !

 

[Trackman417]

What was your riding style like for the axle to snap?

 

[dachopper]

I was pedaling the bike at about 10 km/hr on a road - it had never been off road - ever, or even off Flat road to be precise, there were no modifications to the standard axle at all. The controller was not running the engine correctly at the time of failure - it was as if 80 % of the motor was trying to go forwards while 20% was trying to go backwards..... Or possibly 80% of the duty cycle the motor was forward torque, and 20% rearward torque - which would explain how there was a shock loading strong enough to snap the axle clean in half - no axle twisting seen at all, as I had twin torque arms fitted. Interestingly after the axle snapped, the bike rolled to a grinding halt, and one of the axle sides that was still attached had indeed spun partially inside one of the torque arms - I presume this occurred after the failure as the whole motor weight + me still trying to accelerate went onto one side of the axle only.

how did it happen - there were no instructions with this motor - so I had no idea how tight to do the axle nuts up, I went for very tight, maybe too much - I think I will use much less torque next time and use LOCKTIGHT instead.

Also - I think that a Thicker torque arm with maximum axle face - maybe even 8 - 10mm contact that sits as close to the hub as possible could also relieve the stress on the axle dugout, as the further away the torque arm sits - due to spacers etc, the more it's going to flex.

thirdly - and no doubt the controller juttering was a MAJOR factor in why this has occurred... why it does that when it's first plugged in, before it figures out how to drive the motor - I have no idea as there are no instructions anywhere with the sensorless digital controllers, I just know from what I have seen that something happens when you first plug them in, and somehow the controller either does or does not figure out how to drive the motor - or in this case, snap the axle.

I have 2 controllers - and I have two motors - the HT and the HS - 65 kmhr, and 80kmhr- are the controllers supposed to be different ? I have no idea and did not get told otherwise. when I swapped from the high torque motor to the high speed motor - on the same controller - the motors high speed motor worked fine on first connection.

stumped - now I have to figure out a - where to get a replacement axle from, and b - replace the faulty on off switch..... not happy!

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