12 FET Infineon Controller Problem

[Storapa]

Morning Folks,

I have a 12 FET Infineon controller that is new out of the box. I hooked it up to a Crystalyte HS3540 at the weekend. There was an issue in that the motor would only run for a moment, then cut out. If I released the throttle I could do the same again.

I am using 20s pack so the voltage was around 76 volts. To conduct the tests below I used a test pack at 38 volts.

I connect the motor to an e-bike tester. The halls and phase of the motor appear to be ok.

I then checked the throttle. This also appears to check out ok.

I finally connected the motor controller. There is no 5v light showing on the tester and the controller output test shows nothing. I checked the Mosfets using the Grin Tech method. Everything is ok.

Has anybody else seen this problem and does anybody have an idea as to what it might be? I’m out of ideas at the moment.

 

[Deleted member 4366]

Is it supposed to work at 38v? Did you reprogram the LVC?

 

[Storapa]

Good question. It is supposed to work from 36 to 72 volts with a max voltage of 90 volts. I didn't reprogram the LVC

I will check tonight using the 20s pack (76 volts) and see if it works. I will also check the 5 volt output as suggested by the guys over on Endless Sphere.

I'm a mechanical engineer so this is giving my brain a bit of a workout.

 

[Storapa]

Right, checked for a 5 volt feed from the hall lead from the controlled. Measured 0.3 volts. Checked the throttle and measured 0.5 volts.

I did both of these checks at 76 and them 58 volts.

I'm out of ideas now.

 

[Storapa]

Hi Folks,

Is there anybody in the UK able to check a motor controller?

Any advice on this one would be most welcome.

 

[Deleted member 4366]

You need to check your 5v regulator. It has 3 legs: 12v, 5v and 0v. With the controller switched on but nothing connected apart from the battery and ignition wire, check between the battery ground and each of the three legs. If you don't know what it looks like, take a photo of the pcb at the end where the battety wires join.

 

[Storapa]

Hi,

Thanks for the reply. I think I know what it looks like. I'll check it now.

 

[Storapa]

Hi,

Just measured the three pins on the voltage regulator (test probe sitting on it). Using the battery ground I measure +5 volts on the two outer pins and the mid pin voltage is floating around 9 to 10 volts rather rapidly.

I also noticed that one of the capacitors (?) close to the regulator was rapidly heating up to somewhere in the region of 50C. I used an infared thermometer to measure this.

 

[Storapa]

The component that was getting hot was the smaller capacitor to the upper left of the red test probe.

 

[Deleted member 4366]

I'm not sure that's it. It normally sits near the 12v regulator. Your photo is too dark to see anything.

Can you see any markings on it that include "05"?

 

[Storapa]

Hi Dave,

The component has J3303 on it. Not what I thought it was. The circuit board has TF on it where the other component (the yellow thing) is mounted. Transformer maybe?

Are the attached photos any better?

 

[Storapa]

Can't find a component with 05 on it btw.

 

[Deleted member 4366]

If you look at the back side of the PCB, U1 is a 78L05. It looks like the middle leg is ground and the leg nearest the wires end id 5v.

 

[Storapa]

Morning Dave,

I'll check the component this afternoon when I'm back at home.

Thanks for your help so far. This bit of the project is frustrating. I built the wheel, built a battery box, modified the bike fairly extensively, plugged it all in and got stumped.