Stealth Bomber - Error 07 - Help !

[Rake722]

Hi all we have a 72 V battery fitted to a stealth bomber not so long ago one of the rot bolts became unthreaded and tore into the main harness. We stripped down the hub and repaired it since then it must have short circuit of the controller, so we have replaced the controller with a 60 amp or 65 amp version, the bike worked well for a short period developing error 7 and it’s driving me crazy. Can anybody kindly assist us with troubleshooting this error?

The last time the hub was open I noticed a little bit of bear wire on the whole sensor wires. My immediate reaction is to investigate this however I’d be pleased to understand if there are any tests we can perform before stripping down the hub motor again could be anything else as well.?

Thanks in advance

 

[AGS]

Is this a real Stealth Bomber or a kit bike?

One of the things you can do is a hall sensor test. Here is a good explanation of how to do the test without opening the motor:

https://ebikes.ca/documents/HallSensorTestingFinal.pdf

 

[marty]

Where to find a list of Stealth Bomber error codes? Error 07???

I would contact the manufacturer and ask for a Service Manual.

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[Rake722]

Thank you I would imagine it’s a kit.
So is error 7 certain to be a hall sensor issue ?

 

[TommyCat]

I’d be pleased to understand if there are any tests we can perform before stripping down the hub motor again could be anything else as well.?

Testing BLDC motor's Phase Wiring - Hall Sensors and Wiring. - Electricbike.com Ebike Forum

Thinking a “motor problem” error could also indicate a problem in the wiring BETWEEN the motor and controller…

Regards,
T.C.

 

[Rake722]

Testing BLDC motor's Phase Wiring - Hall Sensors and Wiring. - Electricbike.com Ebike Forum

Thinking a “motor problem” error could also indicate a problem in the wiring BETWEEN the motor and controller…

Regards,
T.C.

Thank you we have tested continuity on the Motor side of the harness to the connector for the controller. We do have continuity on wall wires however we have no voltage at all. This suggest to controller problem?

 

[TommyCat]

however we have no voltage at all.

As in no 5vdc controller regulated power to the hall sensors? Unplug the connector and probe the controller side for voltage.
If still no 5vdc available, try at a different location such as for the throttle. No 5vdc? Ignition circuit used and closed?
Any other operating safeties all closed?

If you have a wiring diagram, controller make and model, or links. More accurate and relevant suggestions could be made.

 

[Rake722]

As in no 5vdc controller regulated power to the hall sensors? Unplug the connector and probe the controller side for voltage.
If still no 5vdc available, try at a different location such as for the throttle. No 5vdc? Ignition circuit used and closed?
Any other operating safeties all closed?

If you have a wiring diagram, controller make and model, or links. More accurate and relevant suggestions could be made.

Thank you for the reply. So far only tested main loom to motor. Will check controller side next and see if there is a brand on the controller but I think it’s generic Chinese

Will come back as soon as I have a chance to test the controller side

 

[Rake722]

As in no 5vdc controller regulated power to the hall sensors? Unplug the connector and probe the controller side for voltage.
If still no 5vdc available, try at a different location such as for the throttle. No 5vdc? Ignition circuit used and closed?
Any other operating safeties all closed?

If you have a wiring diagram, controller make and model, or links. More accurate and relevant suggestions could be made.

OK while I forgot to take a picture of the controller my son tested for the 5v on the controller side and he got 5v as it should do.

He neglected to test continuity from the hall sensor connector to the little pcb’s on the motor so I’ll ask him to do this next.

Would that be the next logical step ?

Thanks again

 

[TommyCat]

not so long ago one of the rot bolts became unthreaded and tore into the main harness.

What’s a ”rot bolt” and is this the harness between the controller and motor?

The last time the hub was open I noticed a little bit of bear wire on the whole sensor wires.

What is a “whole sensor wire”?

We do have continuity on wall wires however we have no voltage at all.

Again, to make sure we are on the same page… what voltage are you looking for, and where?

Would that be the next logical step ?

I would recommend doing a voltage test directly as opposed to another continuity test. (5vdc hall sensor supply Voltage?)
Using both the ground and supply voltage, directly tested at each hall sensor.


This is why.
Say a damaged hall wire is shorting to ground.
It would still show continuity from connector to component, but also short the voltage to ground…

 

[Rake722]

What’s a ”rot bolt” and is this the harness between the controller and motor?

Rotor

What is a “whole sensor wire”?

Hall sensor

Again, to make sure we are on the same page… what voltage are you looking for, and where?

5vdc at hall sensor connector between controller and motor

I would recommend doing a voltage test directly as opposed to another continuity test. (5vdc hall sensor supply Voltage?)
Using both the ground and supply voltage, directly tested at each hall sensor.

Will do

This is why.
Say a damaged hall wire is shorting to ground.
It would still show continuity from connector to component, but also short the voltage to ground…

Understood and will do

 

[TommyCat]

Thank you very much for your answers, much appreciated.

To check the connector, put a test probe on each side of it by back probing, when verifying a voltage carrying wire. An indication of voltage across it would indicate an open or resistance in the connection.
Note: This would include both the RED supply, and the BLACK return wires…