Hall sensor mismatch ! Help !

[KirstinS]

Hi all

Never had this before....

Trying to hook up my new s12s controller to my bpm2 but......it has 5 hall sensor cables and the controller had 6 (an extra white one)

The wiring diagram only shows 5 as well

What's going on here ?

Thanks !

 

[awol]

Just looked and seen I too have the same on my new S12S which I got with an LCD3.
I see it is in the plug position which is normally empty.
I am guessing it's for the temperature sensor if the motor has one as the LCD3 can display this ?
Did your S12S have the old large plugs on the brake cutoffs for their brake levers?

 

[KirstinS]

I also have an extra wire not on the diagram

It's a blue and black with a loop

Like this

 

[Deleted member 4366]

The white wire is for a motor speed sensor. Leave it disconnected. Hopefully, you got the optional wheel speed sensor, which goes to another connector.

 

[KirstinS]

Just looked and seen I too have the same on my new S12S which I got with an LCD3.
I see it is in the plug position which is normally empty.
I am guessing it's for the temperature sensor if the motor has one as the LCD3 can display this ?
Did your S12S have the old large plugs on the brake cutoffs for their brake levers?

Thanks ! That was quick , and yes does have large plugs, I only use one and, like halls, solder directly

 

[KirstinS]

The white wire is for a motor speed sensor. Leave it disconnected. Hopefully, you got the optional wheel speed sensor, which goes to another connector.

Ah no, not got a Speed sensor, didn't know about that as it wasn't onn the wiring diagram which I checked before ordering

Ah well, I guess it will still work? Just not as a Speedo?

Thanks for speed of reply, there are bits all over the kitchen and wife not looking best pleased !

 

[Deleted member 4366]

It won't work without a speed sensor. The controller will go to sleep after a few minutes if it doesn't sense the wheel turning. There's a setting parameter, where you can set the source of the speed sensor. I think you can set it to use the motor halls, which will show a speed as long as you're not free-wheeling.

You can use any cycle computer sensor as a wheel-speed sensor. Just cut it off and join the two wires to the red and signal wire of the speed sensor connector. Naturally, you need a spoke magnet too.

 

[KirstinS]

Ah mine is wireless, need to buy one

Although if I understand right, it will work using the halls if I can fund it setting parameters

 

[KirstinS]

All hooked up but runs very rough, noisy and kind of wavery

Halls colours misaligned ?

 

[Deleted member 4366]

Don't use more than a bit of throttle until it runs smoothly. When I hooked one up to a BPM, it worked first time. It was the same with a Xofo motor. I must be lucky. Assuming that you have good connections, you could try the 36 combinations to see which one gives the best forward running.

 

[KirstinS]

Don't use more than a bit of throttle until it runs smoothly. When I hooked one up to a BPM, it worked first time. It was the same with a Xofo motor. I must be lucky. Assuming that you have good connections, you could try the 36 combinations to see which one gives the best forward running.

Looks like I'll have to do that , all the LCD settings are correct having worked through the manual of g , p and c settings

Giving up fir tonight, too knackered to try and work out the combos !

Cheers for help

 

[KirstinS]

Nope, Brain still can't work this out ! I've made a spreadsheet to check back against but only 25 options as 5 hall (5 x 5=25)

What am I missing here please?

 

[Deleted member 4366]

There's only 3 halls and three phase wires, so there's six combinations of halls for each of six combinations of phase wires, which makes 36 possibilities.

There will be three combinations that give correct forward motion, though sometimes one is slightly smoother than the others. Ideally, you should use a wattmeter to measure the no-load current to find out which is most efficient.

I have provided a table before, which provides a flowchart that shortcuts some of the combinations, but I can't find it now. It was on the Lishui website under FAQ, but they've changed something there now.

 

[KirstinS]

Thanks but I'm really confused now

Coming from the motor I have 3 thick power phase wires. I then have a further 5 thin wires for halls (Green, black, blue, yellow and red )

 

[jhruk]

See: Determining the Wiring for a Brushless Motor

Thin black & red are 5v supply for halls - don't change those.

 

[KirstinS]

See: Determining the Wiring for a Brushless Motor

Thin black & red are 5v supply for halls - don't change those.

Ahhh penny drops !

Thanks
Kirstin

 

[KirstinS]

You can use any cycle computer sensor as a wheel-speed sensor. Just cut it off and join the two wires to the red and signal wire of the speed sensor connector. Naturally, you need a spoke magnet too.

I'm just about to pick up a 5.99 halfords computer to cut the sensor off

My Speed sensor at the controller has a ground wire as well. Presumably this can just be ignored without issue ?

 

[Deleted member 4366]

Yes. The controller only wants to see the signal wire pulsing with 5v. If it doesn't work with the red wire, try the the black instead. It depends whether the signal is pulled up or down. I'm retty sure it's the red wire though.

 

[KirstinS]

I've tried all 36 combo and identified the the smooth, forward ones

But it is still noisy and rough, more so than my ku63 square wave

Hall connection inside the controller perhaps ?

 

[KirstinS]

Looked inside and all looks fine
Halls are well seated

Any ideas ?