What's going on with my ebike? Motor buzzing and won't turn.

[Gloop]

I've had this happen to me 3 times since i got a new 40 amp controller 10 days ago....when i start the ebike and try to apply power it just buzzes and doesn't turn. Then the power cuts out completely sometimes and I have to reset the battery. After a few minute of trying normal function returns and i can apply throttle and ride normally.
I emailed ebikes.ca but they didn't reply...maybe this is a noob question and they don't have time for that.
Anyone know what's going on? I want to go on a 1500 km tour this summer with this motor so i need to know if this is a developing problem or a controller problem or hall problems or whatnot..
Thanks

Oh its a crystallyte DD motor from ebikes.ca and a 40 amp controller both sensored/sensorless from ebikes as well

 

[DanGT86]

Check the hall sensor plug to make sure all of the pins are pushed into the connector all the way. My first controller had the same issue the first time I plugged it in and that was all it was. Grab the wires and push them all towards the end of the connector while you wiggle them around a little. Sometimes during assembly the crimped on terminals dont click into the connector all the way. I would do this on both the motor and controller side of the wiring.

If that doesn't fix it there is instructions on ebikes.ca for how to check the halls with a volt meter. Its a straight forward process to check.

Good luck.

 

[dogman dan]

90% likely it's a bad connection on a wire to the motor. Since it wont run sensor less, I'd look hard at the phase wires.

 

[ColinB]

Hi Gloop,
Don't let that motor buzz for long - it could be drawing huge currents.

I've had good luck with ebikes.ca. Give them a chance to respond, I'm sure they are a busy shop.

Since you have one of the sensored/sensorless controllers, I would unplug the halls for now, and retest. It could be a problem with the phase wires - I believe there are instructions on their site for testing the phase wires also.

Do you have a spare controller you can try? Anything else connected that you can un-plug temporarily, to rule out interference? I'm in Victoria also; maybe I could spot something you don't.

Colin

 

[Gloop]

It happened again today but this time it wouldn't fix itself so i had to get a ride home 5 km.

I never had any problems with my old 25 amp controller over 2500km so i thought it was a controller problem with the new 40amp one....
But i took a closer look at the phase wires on the motor and it looks like one of the pins is broken off.
It looks like there has been some sparking in there too...

I find im always having problems with ebikes...why cant they be reliable like cars.

 

[dogman dan]

More likely the pin backed out of the housing. This happens with andersons pretty easy if the pin gets a tad bent upward. Now you'll know exactly what to look for.

Some just get sick of having a problem like this, and hard solder connect all their motor to controller wires. I just learned to identify and fix that problem. But once I get a good connect, I like to never unplug it. I'll change tires and tubes without disconnecting that wire.

 

[Gloop]

I cut off both 3 pin connectors and soldered them together.......motor still not working.

I never had a single problem with my old controller over 2500 km so i think its the controller.

I'm going to try reattaching my old controller, just need to get it from dads place, and also need a spare anderson..

Another thing ive noticed....the front wheel no longer spins freely when the bike is off anymore...it feels like a bumpy resistance movement. maybe this is normal though

 

[Gloop]

Oh and the motor doesnt even stutter and buzz anymore. It just makes a click when i apply the throttle.

 

[DAND214]

When you cut the connectors off did you turn the motor? Try disconnecting the phase wires and see if it's still hard to turn. If so it sounds like a shorted phase wire if doesn't, it's the controller.

When you soldered the phase wires did you match them up correctly?

Dan

 

[Gloop]

Hi...so i got my old 25 amp controller from my dads house and gave it a test run. Also tested with a spare throttle.
Motor works fine.

So the problem is the brand new 40 amp controller from ebikes.ca. I have had it less than 2 weeks and have been stuck 3 times...now it is completely dead.
I cut off the andersons so i hope they will still honor the warranty...