Help! Dead Short

[jimmydoc]

Hi, my Pulse zr2 ebike battery shorted out when I slid it into place, blowing the fuse . I tested continuity between + and - on the controller and there is a short. I disconnected all the wires from the controller and tested it again where the + and - are soldered onto the controller board, same result. I fitted a new fuse to the battery and tested it on my friend's Pulse bike, its ok. do you think the controller is goosed?
I can send for a new controller from Edbro , but I'm concerned that the fault has been caused by a problem with the motor. Is there any way I can test the motor before I plug it in? Thanks for any help, Norrie

 

[Nealh]

Motors don't cause issues with shorting, they simply don't work. The controller stops this happening.
Your issue is with the battery/docking connection.
If you had continuity on the controller between + & -- then you would have an issue, the two circuits are separate and so they should be.

If the battery was switched on whilst sliding in place then the spark/ short may have caused the fuse to blow or maybe some how pins touched.

You can carry out controller mosfet checks with the meter to see that no short has damaged them, though the fuse blowing is due to a bad batteyr docking connection.
Set dial to dc 200k Black probe to V- and Red probe to each of the three phases wires, you should see about 9 or 10k reading all the same. Next Red probe to V+ and Black probe to the phases you should see infinity or 1 on the same scale.

 

[jimmydoc]

I'll check the Mosfets and battery docking connections and see what I can find, many thanks for your help, Norrie

 

[Nealh]

Going back to why you thought +/- should test for continuity is a strange one as it is a recipe for disaster . It doesn't occur with a battery and if it did you would short out permanently causing damage, possibly fire. That's why your fuse blew (protecting the battery/controller) whilst placing your battery on the bike something shorted between +/-, it may have been the fuse it self failing or some other reason.
The carrier docking contacts could cause the issue if oxidisation has occurred between them due to moisture, this would cause a short. Inside the docking part the wiring is concealed and may have a loose strand that has touched the other contact or equally again moisture may have cause oxidation tracking between the contacts.