problem with ku65 controller

[luckless]

HI, just joined but have read alot, but could not find an answer to my problem. Problem is ,I attached my new ku65 controller to my self build ( unknown motor) 24volt system and it worked imediately, till I turned the throttle off. Since then only the 6 kpm button works. These are second hand parts except the controller. I tested the motor ( has only 3 phase wires ) by shorting out a pair of phase wires at a time and rotating the wheel backwards. Each time I am getting heavy restance. Also checked if there was any shorting to the hub itself( no short ). Have 5v by the throttle and the throttle shows varing voltage when turned. I have a version 7 PAS sensor and a version 5 PAS sensor (the other one I bought to see if the other one was not broken ). I just recharged my li-polymer battery and imediatly checked the voltage. It was 29.2, half hour later 29.2, 1 hour later 29.2, 2 hours later 29.2 . Got fustrated and and left it.Tried it a few times ( once a month ) . Still the same, only the 6kpm button works. Motor fine, battery is fine. 6 Months later I try it again and guess what, it works again, till I let the throttle go. Again fustration. Only the 6 kpm button works. Does any one have an idea what it could be?
Luckless

 

[d8veh]

If the 6km button works, then the controller is working and so is the motor, therefore themost likely culprits are the panel, throttle or PAS.
The panel is easy to test. There'e four wires: red (29v), blue (29v switched by the on/off button), black (ground 0v) and green (signal).The signal wire gives 1V for level 1, 2v for level 2, 3v for level 3 and 4v for 6km button. You now have a choice. You can test the panel with a voltmeter or bypass it. To test it, measure between the black and green wires with it switched on. You can stuff your probes up the backof the connector while it's connected and powered up to get the readings. To bypass the panel, disconnect it and bridge the red and blue wires by stuffing a bit of thin wire in the connector holes or something similar. With the panel by-passed, it works with the throttle and level 1 PAS.

If the throttle then works when the panel's by-passed, the panel is faulty. If it still doesn't work, The next thing is to disconnect the brakes and try again. If still no joy, then you have to measure the voltage between the red and the black throttle or PAS wires, where you should find 5v. If no 5V, check again that the red and blue panel wires are properly bridged, then disconnect the throttle and check again the 5v, then disconnect the PAS and check again. That test will show whether you have a short in any of those items.

Report back after you've done those tests if you need more advise. My guess is that you've got/had water in the panel.

 

[luckless]

I’ve been busy for a few hours, feeling out the actions of the ku65 controller. Voltage of battery after charging 3 days ago is still 29.2volts. Checked 4 wire connector of panel,black + red= 29.2v. Switch on, black+blue=29.2v. Switch on, black+signal green wire gives 1v for level 1, 2v for level 2, 3v for level 3, 4v for 6 km button. So far so good.
Starting up motor for first time, throttle an pas both working good also at high speed until I stop pedeling and throttle to nul. Then only low speed works.Disconected panel and bridged blue and red ( disconnected pas ) throttle works only at low rpm. If throttle passes +/- ¼ turn
, then it turns off (goes to sleep) until you return back to nul and stay under ¼ turn. It is the same if the panel is connected, level 1 works good, low rpm, level 2 and 3 don’t work with throttle. Throttle disconnected, pas connected, pedel power works only in level 1; level 2 and 3 don’t work. Throttle an pas voltage measured at black and red are both 4.3v. not 5.0v
Pas version 5 works better than v7. Ended after a few hours of testing in my shed with a voltage of 28.6v. As far as I can tell there is no short in the wiring and there is no water in the panel because it has not been outside since I bought the controller. Seems to me as if there is a component that cannot consume the extra voltage on the throttle and the panel levels. Can it be a mosfet that is not working well? Is there something else I can test or look at? Still no luck. Thanks for any help.

 

[d8veh]

You need to check what's happening with the throttle while it's connected and not working properly.

First check between the black and red wires by stuffing your probes up the back of the connector. Then measure between the black and the signal wire while you operate the throttle to see its range. It should go from about 1v to 4v.

Are you running with or without motor hall sensors connected?

Make sure that your phase wire connections are nice and tight. Crimp the barrels a bit before reconnecting.

I think you've eliminated the panel as being the cause. I don't think it's a bad mosfet because it works on level 1 PAS but not throttle. It might be worth looking inside the controller to see of there's any bad connections or solder joints.

 

[luckless]

HI. I'm back. Did some more testing of the controller. I am working without hall sensors, the motor has only 3 phase wires. I crimpt the barrels. Tested without PAS connected. Bridged the panel ( connected blue and red ) probes on throttle black+red=4.7V . Probes on throttle black and signal , goes from 0.8V to 3.59V-- Now testing with motor running , At 2V I get Beep Beep coming from my multimeter,continuing further,till I get to 3V and the motor stops ( no power ) Battery is still above 28V . Did the same test but with the panel connected, had the same results rexcept the motor stopped at 2.7V.
Did an extra control of the voltage coming out of the controller, without the throttle and the PAS connected. PAS connector-black+red=4.7V-- black+signal=5.0V. Controller to throttle connector black+red=4.7V--- black+signal=000V . I am not sure if the voltage by the PAS connector should be so. I looked inside the controller and it looks nicely clipped and clean .
Is it possible that at the factory they put the wrong connectors on these wires ( both PAS an Throttle wires use the same colour wires ) or interchanged the signal wires? Just a thought that came to mind. This is getting more complicated.
PS: Tested PAS only, ( throttle not connected ) with panel connected : pedeling--- level 1 works, when switching to level 2, the motor cuts out (stops working ) level 3 also does not work but the 6km button seems to always work , also without PAS and throttle not connercted. I hope that this is giving enough information, I can't think of anything else. Thanks again for all your input.

 

[d8veh]

Your problem is very unusual. I've not heard anything like this before. The only thing I can think of now is a faulty capacitor, so check all the solder joints and that none are swelled at the top.