Motor phase connect to new controller

[tobsie]

Hi,
I installed a new controller on my ebike. After connection the ebike runs again and all the parts are functioning (pas, brakes, throttle, lcd, speed). But only till 20 km/h, then the engine stops. Since the bike at least 25 km/h with my last controller there is somthing wrong. The supplier said there is no max speed set in the controller.
I think I miswired the motor phase wires and/or hall sensor. Because the motor phase wires have different colors on the motor and controller I connected them randomly. Both made sure the the color match is the same as the motor wires on the hall sensor. Could this be the issue? If it is how can I know which motor wire is A, B or C. I only know the phases of the new controller wires, not from the motor. (first pic old controller, second pic new controller, third pic motor phase and hall)
Anybody with usefull info?

 

[tobsie]

None one ho knows anything about this subject?

 

[hjns]

Hi there,

You probably have a false positive combination of phase and hall wires. You will need to mark the phase wires and hall wires, then test all possible combinations of phase and hall wires, record which combination gives what results, and then carefully try the positive combinations. Preferably, you should be able to measure current while activating throttle. With the wheel in the air (no load), a good phase / hall combination would get the wheel turning at topspeed with only very limited current, like 1-2A.

You may want to buy Lyen's motor/controller tester.

If you want to go faster in general, increasing voltage is the easiest way. If your controller is current limited, you can also increase current by adding solder to the shunt, which may increase topspeed as well. As others posted, there may be a white wire that limits speed. Where did you get your new controller, and what are the specs?

 

[tobsie]

I tried all 6 possible combinations now. And I discovered that there are 3 false combinations but identical and also 3 posisitive combination but identical.
So I am 99,9% sure that the issue lies in the controller now. Since I bought this new, I asked the chinese supplier (which assured me that no speed limit was installed). I bought this controller http://www.mxusebikekit.com/shop_show.asp?cid=48 including LCD with speed sensor.
But conclusion is that combination matters!

 

[tobsie]

Or do i need more testing. I assumed that the color combination of the three motor phases have the be the same as the colors of the hall sensor. Am I correct?
So for example the white phase wire from the motor is connected to the blue phase motor wire on the controller. Then I assumed that the white hall wire from the motor also has to be connected to the blue hall wire of the controller. So a match of colors. Does anyone know if this also makes a difference?

 

[dogman dan]

I thought the same. Always match the colors used on the phases with same on the halls. Yesterday I found out not so.

But working out a new controller yesterday with no idea what combo would work, I had quite a bit of trouble finding a combo that ran. Ended up with colors matched on the phases, and b -g swapped on the halls. FWIW, this is a yi yun YK 89 controller on a 5304.

Initially, I was only finding a reverse that worked, which was halls matched, b-g swapped on the phases. Since the controller had a reverse wire, I tried connecting that. Ran great, but half speed. So I thought, lets try swapping the halls instead of the phases. Bingo!

My previous experience was with either sensorless controllers that make it very easy, or Lyens to 9 c which is swap b-g on both halls and phases. I suppose it comes down to which color the gal in the factory feels like soldering to the halls wires to today. It's tuesday, lets solder em all y g b today, yesterday I did it g y b.

 

[tobsie]

Ok thx. The supplier told me that there was an advanced menu for the controller (see image below). They advised to change the value of P1 to 150 instead of the 88 which was default. The motor is know running 29,6 km/h when lifting the front wheel and using the throttle.
I have to make some testrides, because I believe the motor seems a bit less powerful.
But what is the best setting for my motor. I have a 24V brushless motor.

 

[hjns]

Or do i need more testing. I assumed that the color combination of the three motor phases have the be the same as the colors of the hall sensor. Am I correct?
So for example the white phase wire from the motor is connected to the blue phase motor wire on the controller. Then I assumed that the white hall wire from the motor also has to be connected to the blue hall wire of the controller. So a match of colors. Does anyone know if this also makes a difference?

From your last post it looks like you have found a winning combination. However, in my experience there are 36 possibilities, because our chinese vendors usually don't care about colors.