Hall sensors, pinout, how to connect?

[akke]

I have a new 40A controller from ebikes.ca and a 400 series rear motor (Crystalyte 408) but both the motor and the controller have a 5-pin female hall sensors connector.
So I guess either the motor or the controller should have come with a male connector instead but this is what I have right now.

Can anyone tell me how to connect them together? Is it safe to assume a color-color match? Is it possible that I'll damage the hall sensors if the wiring is wrong? If so, is there a way to find out the correct wiring without damaging the hall sensors?

Thanks

 

[Ykick]

Color - color? Probably not. You'll need to gently test for valid combinations. This thread has a great chart and discussion about how to "find" a valid combination:

http://endless-sphere.com/forums/viewtopic.php?f=2&t=48311&p=711552#p711552

Sensors are fairly hardy but you can blow MOSFETS inside controller easily with incorrect combinations and too much throttle-load.

 

[999zip999]

Red to red and black to black to start. The other combo's are the trick. AS mention earlier go very light on the throttle will triing to firgure this out. Do you have a battery strong enough for a 40amp controller ? Yes it is the controller that kills a battery with it's amp demands. the battery has no brains just a heart and you can kill the heart.

 

[akke]

I have a battery capable of delivering 50A continuous load so the 40A controller should be fine.

The controller I got from ebikes.ca is a sensored/sensorless controller. It seems to be able to rotate the wheel without the hall sensors connected. I didn't try connecting the hall sensors yet as I was not sure about damaging the hall sensors. But it seems that connecting red=red and black=black should be safe to start with...

On ebikes.ca (here: http://www.ebikes.ca/troubleshooting/PinoutGuide.pdf) they show how to connect the infineon based controller to a crystalyte motor. Doing that (without the hall sensors for now) resulted in a wheel spinning backwards. While connecting it color-to-color rotated the wheel forward ... I tried a couple of combinations and I can't tell the difference. Seems like this motors rotates pretty smooth with multiple combinations, when the hall sensors are not connected.

I'll try connecting the hall sensors later today. I guess I'll have to try 36 combinations just to find out which combinations rotated the smootest with least current draw

 

[teklektik]

I have no personal experience with the Grin Tech dual mode controllers but their web site claims:

... So if the hall cable is not connected, they will automatically engage in a self starting sensorless mode, and if the halls are later plugged in the controller will automatically map the hall table and run sensored so that you don't have to play around with hall/phase pinout combinations.

This seems to suggest that once the red/black power leads are connected, you can connect up the hall sensor leads any old way and things will work. It actually seems that this behavior may defeat any attempts to discover 'the right' combination since they will all work....

Please post back with you experiences in hooking this up - sounds pretty cool.

 

[Ykick]

I have no personal experience with the Grin Tech dual mode controllers but their web site claims:

... So if the hall cable is not connected, they will automatically engage in a self starting sensorless mode, and if the halls are later plugged in the controller will automatically map the hall table and run sensored so that you don't have to play around with hall/phase pinout combinations.

This seems to suggest that once the red/black power leads are connected, you can connect up the hall sensor leads any old way and things will work. It actually seems that this behavior may defeat any attempts to discover 'the right' combination since they will all work....

Please post back with you experiences in hooking this up - sounds pretty cool.

Damn good point! Sorry OP, I don't know that controller so best confirm how it works before attemtping combos?

 

[akke]

Well, I wired it by matching the colors for phase and hall sensors, this was actually the first combination I have tried and it seems to work fine.
I just did a test by riding about 8km and didn't encounter any problem so far. So I think it's all okay

 

[999zip999]

Thanks for coming back and letting us know as some just ride off into the sunset. Let us lnow of a problem.