Help! Santroll 72V controller issue

[Greenwheelstanzania]

Hello!

We are running an Electric motorcycle taxi fleet in Tanzania.
Now we are experiencing the following issue with one of our bikes/controllers:

When accelerating the throttle, the engine magnetizes and the hub engine stays stuck in place.
What we did so far:

- exchanging the controller to determine the controller as the issue.
- exchanging hall sensors inside the controller
- testing mosfets
- exchanging one of the two circuit boards to determine on which one the problem is.

Now that we know where the problem is we cant find out What the problem is.
I will ad a picture of the troubled circuit board.
Anyone have an idea what it could be?

Thank you!

Best

Rico

 

[E-HP]

Do you mean that you replaced the hall sensors in the motor (not controller)?
It sounds like a stuck motor due to incorrect phase and/or hall sensor conductor combination.

Testing BLDC motor's Phase Wiring - Hall Sensors and Wiring. - Electricbike.com Ebike Forum

Testing electrical components of a typical hub motor with a digital multi meter. First take a few minuets and look over the wiring going into the motor for cuts, scrapes, missing insulation and other wiring issues or poor connections that should be resolved first. Smell for...

electricbike.com

 

[Greenwheelstanzania]

Hello, thanks for the reply. no, we replaced the hall sensors in the controller.
The motor is fine and currently running in another bike. We can 100% be sure the issue lays in the pictured circuit board.
As we exchanged and tested every other possibility.

 

[E-HP]

So you tried all 36 wiring configurations?
Just curious, what functions do hall sensors perform in a controller?

 

[Greenwheelstanzania]

I am also not sure about the function of the hall sensors in the controller.
iItst's not necessary to try wire configurations if you can simply exchange a controller or part of it with a functioniong one.
If it works after the exchange, you know the source of the problem.
Very easy way to narrow it down to this circuit board like that.

 

[AGS]

I think the op is talking about the hall sensors that sit in the air gap of the toroids in the controlller. These are used to measure the motor phase currents.

 

[Greenwheelstanzania]

I think the op is talking about the hall sensors that sit in the air gap of the toroids in the controlller. These are used to measure the motor phase currents.

thanks for the info. good to know!