Upgraded my controller and battery, but now lower top speed?

[ndawsonelli]

Hey guys,

So this will be my third ebike build - one with hobbyking lipos and a lyen controller that worked great, one with a home-built battery and 20 dollar chinese controller that also worked great, and then.. this one. I got a Lunacycle 20S (~84V hot) battery pack and am using a Lyen 124110 controller, the same one that I used before, with the same motor - but now there is a lot more noise, it pulls enough amps to heat up the wires when spinning freely, and refuses to start under load (like if I'm sitting on the bike). I still have the old battery and controller, and hooked those up and they worked like a dream, but still can't get this one to work. It seems like it has to be a timing issue, nothing else really makes sense, and the motor spins with the hall sensor setting at 120 degrees and not at 60 degrees, but the phase wires get extremely hot - like 60C within 10 seconds, just freely spinning off the ground. The speed of the motor is also heavily dependent on the battery current / phase current limitations that I set in the software, which definitely shouldn't be the case if it's spinning with essentially no load. Compatibility mode results in the same thing, so I'm assuming it's just using 120 degrees.

The throttle is a hall-effect sensor type, which goes from 0.8V-3.6V, which is narrower than I'd like, but the same thing happens when I hook up a 10k pot in its place, which goes from 0-5V.

Any advice?

-Neal

 

[Ykick]

Motor timing I bet.

https://endless-sphere.com/w/index.php/Determining_the_Wiring_for_a_Brushless_Motor

Edit to add - Might wanna check controller MOSFETs? http://www.ebikes.ca/learn/troubleshooting.html

 

[ndawsonelli]

Awesome, thanks for the response and the links!

I followed the first one and found a new combinations that freewheels perfectly, but when I ride it, it provides almost no torque, is fairly loud and very jittery, and the wires still get hot fairly quickly. Then, I went through and tried every other combination and still didn't have any luck.

I tested the controller for blown MOSFETS, and they all seemed fine - perfect 10k to ground, and my fluke said -.5Mohms to the hot wire, though I'm not sure how it can be negative. I assumed it meant infinite, for all intents and purposes.

It still seems like motor timing but I'm not sure how to go about troubleshooting further.

 

[Ykick]

shorting any pair phase power wires (disconnected from controller of course) should make the motor considerably harder to turn by hand. Conversely, phase wires not touching each other should be noticeably easier to turn motor by hand.

At this stage of the problem, I would go through every pair of phase wires shorting and not shorting them to look for this behavior. This might help qualify the phase power wiring and motor windings?

Good luck

 

[ndawsonelli]

Apparently I just wasn't thorough enough - following the plan outlined in this image

[https://endless-sphere.com/w/index.php/Filehase-Hall-Wire-Combinations.png] got me to the right combination this morning and now it's practically a rocket ship. Thanks again!!

 

[Ykick]

Right on! Glad you got it sorted out and thanks for the update...