Hub motor locks when given throttle

[Izzy2004]

Hey guys,

So I decided to spruce up my phase wires one afternoon and after finishing and plugging everything back together my motor wont spin. When given throttle it locks up and my voltage gauge drops. Seems this thing is taking in so much darn current. I went ahead and un-globbed my shunts on my controller but alas same issue. Controller says everything is a-okay (Its a YKZ7280) on the app. So my question is this what causes a motor to lock up when given juice. I did hall tests and rotating the wheel doesn't make the voltage bounce from 0 to 5. Thing is i checked the hall connections and they look just fine. I never even touched the things just the phase wires. Any ideas?

 

[BionicBlitz]

a loose/ broken phase wire will do this... be real careful about it but try giving it a tiny bit of throttle (less than 5% ) and spin thewheel by hand slowly if it does nothing then quickly jumps (and probably trips your over current shut off) then its a phase wire is disconnected. if it doesn't do that it could be you scratched the wires when you pulled them through the axel and its a direct short.. but feel like youd hear/see sparks if thst was the case.. could be a bad hall connection. what all did you do to the bike?

if you have a multi meter put it on tge resistance setting and mesure the resistance of each phase

again, if you try that little test be very careful, can fry your controller.

 

[Izzy2004]

Thanks for the quick reply ill check that because it was indeed hard fitting bigger gauge wires though that little hole. One thing happened one time when I was testing different phase combinations was there was a spark at the phase wire connection where the controller/wheel wires meet. Don't know what thats about. My controller seems to be ok as the app says all is good and it still has functionality in terms of what i read off the multi meter. From my readings I did notice shorting is easy so I guess Ill go ahead and re-solder every wire on that damn motor. I checked the controller thoroughly and it's still good. Seems to have very good safety built into it. I have a feeling that my short could be the copper inside the motor touching the cover. Also the motor spins pretty freely but as I short the phase-wires together there is resistance in the turning. If you got any ideas please do let me know for now Ill go check the motor.

Thanks!

 

[MadRhino]

If you just changed the phase wires, either you have a short or you mixed up the connecting order (phases or halls).

Since a short does usually fry the controller, I’d look for the phase and hall combo first.

 

[E-HP]

Hey guys,

So I decided to spruce up my phase wires one afternoon

What's that mean?

 

[Izzy2004]

The sprucing meant switching to 10AWG from the 18 or whatever was there before. So... After many many hours.. I checked the controller and all the Fets, all the caps and lines I have no idea, it seems to be in perfect shape. The motor I basically cleaned and rebuilt no shorts, all wires connected. But when the two are combined its a gongshow. Basically something is up with the hall. It doesn't matter if the hallphase wires are in or not its the same twitch the motor does. It's like it doesnt even want to detect it. Controller just outputs 0.8V , 5V, 5V only. I cant figure out which is the broken component..<

 

[Izzy2004]

One of my halls burnt out thats what happened. Now gotta wait for shipment of replacement ones.

 

[BionicBlitz]

oh darn.. luckily nothing too serious but still a pain

and the motor slowing down or is hard to turn when you short the phases because its basically a generator, puts put power when you spin it, lots of peoole use tgem as wind mills. (that how the regen braking works) so nothing to worry about there :}

 

[Izzy2004]

Im guessing the added gauge straight fried those old unbranded 41Fs...I ordered 10 new honeywell ones. I don't know much about hall sensors but maybe there are compatible ones but are more sturdy when it comes to high current?

 

[BionicBlitz]

not sure.. never had issues with them. maybe research what kills halls and see if you can avoid that situation.. if youre adding beefier wires im guessing youre over volting/ running extra current? so maybe its the heat

 

[Izzy2004]

Over volting? I mean this motor doesn't seem to ever get hot and they are always rated ridiculously. 500w motor ridden at 2000w seems to be no issue. I think the hall fault was me sorting it accidentally and giving it full throttle. Got some SS41F's coming in Monday. Fed-ex overnight but they just have to have weekends off.