Hall sensor connection

[Nealh]

Those figures are good, your 03 error then is a wire issue so somewhere you have a faulty wire /connection.
Make sure the motor connector is pushed 100% all the way in or has no bent misaligned pin inside.

 

[UrbanPuma]

That’s good news and indicates your hall sensors are working correctly. Now do the same on the pas between white and black by rotating the pedals very slowly.

Your pas sensor may have a red light that will flash on and off as well.

Great. I'll do in the morning, AGS and report back. Have a good evening, thanks

 

[AGS]

Tomorrow is fine, because you are going to hate what we are going to ask you to do next.

 

[UrbanPuma]

Those figures are good, your 03 error then is a wire issue so somewhere you have a faulty wire /connection.
Make sure the motor connector is pushed 100% all the way in or has no bent misaligned pin inside.

Ok, good to hear Nealh. I'll check in the morning and provide an update. Have a good night, thanks.

 

[saneagle]

If you still get the 03 error after you check your motor connector, it could be because you have a short on the 5v somewhere, like when you get wires in the wrong sequence on connector, so disconnect everything from the controller except the motor, battery and LCD to see if the problem goes away. If it does go away, then you can connect theings back one at a time to see which is wrong.

 

[UrbanPuma]

If you still get the 03 error after you check your motor connector, it could be because you have a short on the 5v somewhere, like when you get wires in the wrong sequence on connector, so disconnect everything from the controller except the motor, battery and LCD to see if the problem goes away. If it does go away, then you can connect theings back one at a time to see which is wrong.

Thanks Saneagle.

That’s good news and indicates your hall sensors are working correctly. Now do the same on the pas between white and black by rotating the pedals very slowly.

Your pas sensor may have a red light that will flash on and off as well.

Ok, AGS I'm going to perform this test now.

 

[UrbanPuma]

Afternoon everyone. I'm about to test PAS now and will report back. These are my wire connections with pas.

 

[UrbanPuma]

If you still get the 03 error after you check your motor connector, it could be because you have a short on the 5v somewhere, like when you get wires in the wrong sequence on connector, so disconnect everything from the controller except the motor, battery and LCD to see if the problem goes away. If it does go away, then you can connect theings back one at a time to see which is wrong.

Thanks Saneagle. The error code comes up when I turn the throttle. I can't get the pas to come on when I turn the wheel either. What do I do once I disconnect pas?

 

[UrbanPuma]

Great. I'll do in the morning, AGS and report back. Have a good evening, thanks

Hi AGS, just tested PAS. It's very difficult to get it to alternate between those two numbers below (the wheel requires much more turning (seems more spaced out) to get the change otherwise they just stay on the same number).

Black + white = 506 - 001

 

[AGS]

You have to fix the problem that gives error code 03 otherwise nothing will work. The red and black wires must be ok otherwise you wouldn’t have been able to supply voltage to the hall sensors yesterday. So carefully inspect the connections for the yellow, blue and green hall wires.

I don’t understand your test results for the pas. You should see a voltage swing between 0v and 5v. When you turn the pedals the magnetic disc rotates around the pas sensor, so if you have a 12 magnet pas, then the voltage will swing 12 times per revolution. If you rotate too fast then you won’t see the voltage swing properly. It has to be done slowly.

It’s better to disconnect the throttle for the time being and concentrate on getting the pas to work. If your throttle is wired incorrectly then that will hinder the testing. You should only test one input at a time at this stage. And if you have brake cut offs, then disconnect them as well until you get the motor to run properly.

Also you must set the display to pas 1 for the tests. If it is set to pas 0 then nothing will work.

 

[UrbanPuma]

You have to fix the problem that gives error code 03 otherwise nothing will work. The red and black wires must be ok otherwise you wouldn’t have been able to supply voltage to the hall sensors yesterday. So carefully inspect the connections for the yellow, blue and green hall wires.

I don’t understand your test results for the pas. You should see a voltage swing between 0v and 5v. When you turn the pedals the magnetic disc rotates around the pas sensor, so if you have a 12 magnet pas, then the voltage will swing 12 times per revolution. If you rotate too fast then you won’t see the voltage swing properly. It has to be done slowly.

It’s better to disconnect the throttle for the time being and concentrate on getting the pas to work. If your throttle is wired incorrectly then that will hinder the testing. You should only test one input at a time at this stage. And if you have brake cut offs, then disconnect them as well until you get the motor to run properly.

Also you must set the display to pas 1 for the tests. If it is set to pas 0 then nothing will work.

Ok, will be back soon

 

[Nealh]

You have to fix the problem that gives error code 03 otherwise nothing will

Yep 100% agree .

 

[UrbanPuma]

You have to fix the problem that gives error code 03 otherwise nothing will work. The red and black wires must be ok otherwise you wouldn’t have been able to supply voltage to the hall sensors yesterday. So carefully inspect the connections for the yellow, blue and green hall wires.

I don’t understand your test results for the pas. You should see a voltage swing between 0v and 5v. When you turn the pedals the magnetic disc rotates around the pas sensor, so if you have a 12 magnet pas, then the voltage will swing 12 times per revolution. If you rotate too fast then you won’t see the voltage swing properly. It has to be done slowly.

It’s better to disconnect the throttle for the time being and concentrate on getting the pas to work. If your throttle is wired incorrectly then that will hinder the testing. You should only test one input at a time at this stage. And if you have brake cut offs, then disconnect them as well until you get the motor to run properly.

Also you must set the display to pas 1 for the tests. If it is set to pas 0 then nothing will work.

1. I've included a pic of my throttle wired up and connected.

2. PAS reading was 1 then hardly moved when turning..it went to 0.03, but didn't really alternate.. definitely not consistent readings as halls yesterday.

3. I'll double check the yellow, green and blue hall wires and report back.

4. Do you mean set all five P display settings to 1?

I re-soldered phase wires yesterday, could that cause the problem?

 

[AGS]

“4. Do you mean set all five P display settings to 1?”

No I mean the PAS assistance level, which can be set from 0 to 5 on the display using the up and down buttons. It’s easy to forget to set it when testing. If you leave it at 0 then PAS and throttle won’t work.

But you need to get rid of error code 03 before doing anything else.

Sometimes the barbs on the pins get damaged or flattened and when you click the connectors together the pin gets pushed out the back of the connector and you lose contact.

 

[UrbanPuma]

“4. Do you mean set all five P display settings to 1?”

No I mean the PAS assistance level, which can be set from 0 to 5 on the display using the up and down buttons. It’s easy to forget to set it when testing. If you leave it at 0 then PAS and throttle won’t work.

But you need to get rid of error code 03 before doing anything else.

Sometimes the barbs on the pins get damaged or flattened and when you click the connectors together the pin gets pushed out the back of the connector and you lose contact.

Ah ok. It was on 5. I'll set to t to 1. Thanks. Those barbs are so fiddly - I'll double check them and report back tomorrow.

 

[saneagle]

Thanks Saneagle. The error code comes up when I turn the throttle. I can't get the pas to come on when I turn the wheel either. What do I do once I disconnect pas?

You must have the throttle on the wrong connector and/or, the connection sequence is incorrect.

 

[UrbanPuma]

You must have the throttle on the wrong connector and/or, the connection sequence is incorrect.

Hi Saneagle, sorry I hadn't checked if pas produced the error code before, but did a check last night with pas plugged in and turn of the wheels and 03 info error code flashed too, so appears it's happening when I activate both throttle and pas.

Please see attached pic of throttle connection and controller throttle wires - let me know if it's wrong. Thanks.

I'm going to check the hall sensor pins today and report back to everyone.

 

[UrbanPuma]

Morning everyone, I put a 3 pin throttle connector on my old controller as it had 4 pins so that I could test to see if the bike still worked and it did. The issue I was having with old controller was that it was switching to max speed and stuck there until brake applied (which is dangerous). It happens intermittently. Someone mentioned blown resistor likely cause - what do you think?

My battery on/off switch light is not stable when turning on and off light flickers and sometimes comes on other times doesn't - don't know if this has anything to do with issue with throttle?

Is it fair to assume because bike works (pas and throttle) with old controller this means the hall sensors are connected properly when I switch back to KT controller?

 

[AGS]

It means the hall sensors are working and the wiring to the connector is ok, but you already tested them the other day.

If your new controller doesn’t work then you still have wiring issues with your new controller if you are still getting the 03 error. The symptom still suggests a bad connection between the plug and socket for the hall sensors. Bent or broken pin maybe?

There are other things you may need to do regarding swapping hall and phase wires to get your motor to run with the new controller, but the 03 error must be fixed before you can move on to the next step.

 

[saneagle]

Hi Saneagle, sorry I hadn't checked if pas produced the error code before, but did a check last night with pas plugged in and turn of the wheels and 03 info error code flashed too, so appears it's happening when I activate both throttle and pas.

Please see attached pic of throttle connection and controller throttle wires - let me know if it's wrong. Thanks.

I'm going to check the hall sensor pins today and report back to everyone.

OK, I misunderstood what you meant. If I had your bike in front of me, I'd have it sorted in one minute. The problem is to know what you're saying and what you've done.

If I understand correctly now, when you connect everything and switch on, all is OK. The LCD lights up and shows everything normal, then when you tell the controller to give power, you get 03 error code.

If you're sure that the motor cable is OK and it's properly connected, you must have the wrong connection sequence, so you should go through all 36 combinations of three phase wires and three hall wires until you find one of the three correct ones.

Before you do that, where exactly did you check that the halls were switching - on the controller side of the connector or the motor side? If motor side, do it again on the controller side.