Solar Boat Kelly Controller KLS 2435ND Errors 3,4 and 1,1

[omard]

Hello all,
Our High School is building a solar boat and we're having an issue with with 1 of our Kelly Controllers. KLS2435ND controller wont complete Identification angle process. Motor rotates and ticks about 7 times then nothing. We've left it at this stage for 10-15mins. Opening the KMC User app on laptop shows Faults: Identity and Hall.
According to User Manuel we can rewrite 85 at this point User app. When we do we get the following beep codes: Errors 1,1 (automatic error identification) and 3,4 (angle sensor error).
This is the second motor and controller, first pair had no issues. We check all connections and can't find any issues in our wiring.
We are scheduled to complete in a regional endurance and drag race this Saturday. Our students have been working on this project all year. They would be devastated if we can’t fix this. Please help.

 

[Jeff23spl]

have you checked the hall sensor signal when slowly rotate the motor to make sure they all works. Wiring may be good but not the sensors. it is like a pickup coil that change state when seeing the magnet poles.
if you have 2, have you swaped controllers to see if motor is the problem or the controller side ?