Help with cogging Hub Motor

[e-beach]

Replacing your motor and controller would give you a functioning and usable cycle. IMO that would be the highest degree of confidence of a dependable cycle.

Trying to repair the old controller is a bit of a crap-shoot. Finding that mosfet will be your first problem. Finding an equivalent might be easier but not cheap.

It is usually recommended that you replace all the mosfets at once to have consistency. I don't know what that means for your other controller you haven't opened.

And, once your new mosfets are in they still might fry depending on weather anything else is blown on that board. It is conceivable that you could spend $30.00 for 2 mosfets, spend the time to install them and still not get your controller working. Not to mention repairing the heat sync.

The other option is to simply get another controller. Or maybe 2 controllers and run them like your two old controllers. 2 controllers could be risky if they are not syncing properly.

Did you ever ride your cycle around on only one controller? IF so, was the motor getting hot?

Edit: Might be possible to use something like this...Contact Grin.....http://www.ebikes.ca/shop/ebike-parts/controllers/c-bac2000.html

Have you contacted Kelly and explained your dilemma?

Edit: Also, contact http://www.lyen.com/ and see what they say.

 

[e-beach]

Could roll the dice........

http://www.digikey.com/product-search/en?keywords=IXTP130N10T

 

[__Tango]

I may give repairing the controller a shot, but probably not. I pulled the trigger on a Revolt RV-160 Short and am having fun trying to figure out how to make that work.

 

[japperrrr]

Hey Tango, I have the exact same motor as you have and it has the same problem. Only the cause seems to be different.

Few months ago it started shaking and I found out that it runs smoothly when I disconnect one pair of 3 phases. Basically, I can drive on either phase groups, as long as I only connect one group of 3 and don't connect the other 3 phases. First I thought that the controller was broken so I bought two 9 FET Lyen controllers to replace my 6 phase controller. Though, there was no visible damage on the controller and all FET's measured OK.

Then I connected each Lyen controller to a group of 3 phases and ran them individually. Both controllers were able to get the motor running without any problems. And guess what? When I turned on both controllers at the same time, the motor started to vibrate again. That got me thinking that not the controller, but the motor itself was the problem. The hall sensors were functioning so that couldn't be the problem.

This pretty much left me with no other choice than to open up the motor (photos on request). I found that internally there is some sort of dual 3 phase WYE setup. Which again got me thinking. If the motor is pretty much a dual 3 phase motor, then there shouldn't be any internal connection between the two groups. Though, I do actually measure a connection between both groups while visually there doesn't seem to be any.

It makes sense that U1, V1 and W1 are connected because they are in a WYE setup. For the same reason it also makes sense that U2, V2 and W2 are connected. Now what I mean is that in my situation, all phase wires are internally connected to each other. So for example when I measure U1 to V2, it gives me the same result as U1 to V1.

Could you do me a huge favour and measure the resistance between your phase wires? Would help me a lot!

 

[__Tango]

Do you think it's really a 6 phase controller? I thought it was basically two 3 phase in parallel.

I don't know that much about motor setup, so I'm just guessing.

In any case, I can measure the resistance, but I'm not sure of what combinations you want.

 

[japperrrr]

The controller that came with it has been custom designed by the Dutch manufacturer. It is one PCB but it consists of two 3 phase controllers. That's also why I tried to replace it a pair of Lyen controllers.

Since the motor has 6 phases it also has 6 phase wires. I need to know if the two groups of 3 phases each are connected to each other, or if they are isolated. The answer can be found by measuring the resistance over the phase wires. You simply take take 1 of the 6 phase wires and measure its resistance over the other 5 phase wires. If the groups are isolated, you will measure a connection with only 2 out of 5 remaining phase wires. While if both groups are internally connected, you will measure the same resistance/connection over all 5 remaining phase wires.

 

[__Tango]

The controller that came with it has been custom designed by the Dutch manufacturer. It is one PCB but it consists of two 3 phase controllers. That's also why I tried to replace it a pair of Lyen controllers.

Since the motor has 6 phases it also has 6 phase wires. I need to know if the two groups of 3 phases each are connected to each other, or if they are isolated. The answer can be found by measuring the resistance over the phase wires. You simply take take 1 of the 6 phase wires and measure its resistance over the other 5 phase wires. If the groups are isolated, you will measure a connection with only 2 out of 5 remaining phase wires. While if both groups are internally connected, you will measure the same resistance/connection over all 5 remaining phase wires.

I took measurements. The groups are isolated. The resistance is 0.25 ohms with two of the other three wires in a group, whereas open with the other group of three wires.

 

[japperrrr]

Well, I guess that my motor must be broken then. Thanks for the help though. If you would ever want to get rid of yours, at least you know know who needs one haha :lol:

 

[e-beach]

.......The groups are isolated. The resistance is 0.25 ohms with two of the other three wires in a group, whereas open with the other group of three wires.

@ __Tango .....Hummmmm......Ok, then this does mean you could drive your cycle around on one set of phases and one controller, probably not as hard as with both phases, but maybe you can double up with 2 controllers being that your phases seem to be good.......?

At least you could cruse around town until your new motor is ready to go.

 

[__Tango]

.......The groups are isolated. The resistance is 0.25 ohms with two of the other three wires in a group, whereas open with the other group of three wires.

@ __Tango .....Hummmmm......Ok, then this does mean you could drive your cycle around on one set of phases and one controller, probably not as hard as with both phases, but maybe you can double up with 2 controllers being that your phases seem to be good.......?

At least you could cruse around town until your new motor is ready to go.

Yeah, true. I also have my VF500 conversion (using an Enertrac MH602 hub motor), so I'll just ride that instead.

(until I pull the thundersky batteries out of that to replace with Enerdels)... :-D