QS205 Hall sensor Replace and Fix

[MDG]

Hello, I have an extra QS205 V3 hub motor that was giving me a 0000008 fault code in my Votl tuning software.

A few months back I had accidentally spliced through a phase wire with the brake rotor. Seemed to fix it ok as it worked for a while. Then stopped again.

Took the motor apart this morning and noticed one of the hall sensors actually detached itself from the circuit board.

Is there a way to re-solder these sensors directly to the wiring instead of using the circuit board?

There’s also an extra red and black wire that go inside the coil windings and not sure what they do? The extra long black wire went to the other side board but that board is no longer connected….long story.

I attached some pictures. Maybe it’s best to just get a new board and sensors?

Thanks!

 

[MDG]

I was thinking of hard wiring it like this.

All red 5V+ to the corresponding red harness
Blacks to black -
Then each hall color wire to its corresponding G, Y, B

 

[MDG]

Found an oldie but goodie QS video of someone hardwiring hall sensors. Think I answered my own question with this. I see he branched off like in my drawing 3 separate wires from each the red and black wires from the wiring harness. Then soldered the corresponding Green, Yellow, Blue wires.

Guess now I’ll order some Honeywell SS41 sensors.

 

[MDG]

Does anyone know if this is a temp sensor?

 

[braunschweiger]

two wires - not enough for another (rpm-)hall sensor;
temp-sensor test: measure resistance, apply little heat & measure again - significant change? => heat sensor

 

[MDG]

two wires - not enough for another (rpm-)hall sensor;
temp-sensor test: measure resistance, apply little heat & measure again - significant change? => heat sensor

Thanks! I’ll check it out later.

 

[MDG]

@braunschweiger I did the voltage test on that sensor with a heat gun and sure enough the voltage went up as the area warmed up a bit. Then dropped as it cooled.

Do you know if this needs to be connected when I re do the halls? I plan to remove the board all together and do not run a temp gauge. Thanks for all your input!

 

[braunschweiger]

Usually the temp sensor is only read and interpreted by your controller, if at all. From there it depends on the controller's firmware and settings what it does with that temp info. It _could_ reduce current to the motor or even shut the motor down upon temp exceeding thresholds. Or it could only make the temp available for reading via the display. Or it could ignore temp altogether.

I have a motor without a temp sensor inside. My controller interprets this non-existent sensor value motor temp as some motor temp below freezing. Irritating, but no problem if you run your motor within its safe limits.

Bottom line: the motor temp sensor most likely works as a safety measure (if your controller makes use of it). Probably will not matter if you leave the sensor not connected. You lose an additonal safety feature.
If wiring inside the motor is easy enough and your controller has a connector for motor temp sensor input, then use it.

 

[MDG]

Usually the temp sensor is only read and interpreted by your controller, if at all. From there it depends on the controller's firmware and settings what it does with that temp info. It _could_ reduce current to the motor or even shut the motor down upon temp exceeding thresholds. Or it could only make the temp available for reading via the display. Or it could ignore temp altogether.

I have a motor without a temp sensor inside. My controller interprets this non-existent sensor value motor temp as some motor temp below freezing. Irritating, but no problem if you run your motor within its safe limits.

Bottom line: the motor temp sensor most likely works as a safety measure (if your controller makes use of it). Probably will not matter if you leave the sensor not connected. You lose an additonal safety feature.
If wiring inside the motor is easy enough and your controller has a connector for motor temp sensor input, then use it.

Thanks for the helpful information. I am using a Votol EM100 controller and I know on the “display” portion of the tuning software there is the “temp” area. Just don’t want to put this all back together and have a temp error code.

I’ve ran plenty of 138 V3 mid drives with Votol controllers but they don’t have a temp sensor so wasn’t sure being that the 205 hub motor comes with one if I need to adjust or turn off a setting in the software.

 

[MDG]

Well we are back in action! Feels great to have taken this motor apart and fixed it for $20! Saved me a few hundred dollars in replacement.

I didn’t take pics but it is a bit tedious amount of small wire soldering and making sure everything is covered and protected.

I used high heat red RTV to help seal and hold things down along with some HD zip ties and waterproof lined heat shrink.

I did not wire up the KT temp sensor and changed my settings in the Votol software port settings for PA0. I changed it from (38) ext. temp sensor to (1) empty function.