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BLDC Motor Troubleshooting: Rotor attempts to turn, but cogs in place...

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EEdwards15:
Hello there!

THE CONTEXT: I'm setting up a GM BLDC motor and controller. I'm currently powering the motor with a portable power supply as to avoid blowing up any (muy expensive) large format batteries.

THE PROBLEM: Every time that I turn the throttle, the rotor cogs in place. It's trying to turn, but can't make it more than 10deg or so... At first I thought that this might be a mismatch in advance angle parameters, but now I suspect that it may be related to minimum current requirements of the motor/controller and/or a throttle issue.

HARDWARE DETAILS:
20kW/96V GM BLDC Motor
20kW/96V GM VEC-700 Controller
Power Supply at 83V and 15A (1245 W)

SOFTWARE DETAILS:
PI-800.exe with default parameters EXCEPT...
    -Rated motor speed: 3500 rpm (Default was 6000 rpm despite the motor being rated for 3500... not sure what's going on there)
    -Battery drawn current limit: 15 A (Default was 250 A)
    -"EBS enable", "Cruise Control Enable", "Cruise Control Manual Mode Enable", "Boost Enable" are all DISABLED


Two screenshots of the default parameters are attached for reference. The parameters not mentioned above are set at the default parameters.

THE QUESTION: What am I doing wrong such that the rotor refuses to turn? Is this one of the several throttle issues that I've seen discussed in the forums? Is my battery current (15 A) insufficient? [NOTE: I'd like to avoid connecting my large format batteries until I can confirm that everything is working correctly... and 15 A is the max current that my power supply can handle.] My "hall electrical angle" and "phase angle offset" parameters (120 and -120, respectively) are set to their default values... but is it possible that this might be incorrect as well?

Any help is greatly appreciated! Please let me know if you need any additional details.

-EE

Bikemad:
Hi andto the forum.

Most of the throttle problems with the VEC controllers is basically that they don't control the motor speed very well when there is no load on the motor. I seem to recall that the throttle actually controls the motor's torque rather than its rpm.


--- Quote from: E-Chopper on March 30, 2015, 12:51:44 PM ---I test the set- up with load and it work .
Only with load you can control the Throttle.
Without load the Throttle goes up from 0% direct to 100% with no steps between .

--- End quote ---

Have you checked that the settings are actually being saved correctly by re-loading them again to update the figures?

The only thing I can suggest is to try lowering the Starting phase current to 15 Amps (if it's possible) and the Rated phase current to 20A to see if it makes any difference.

If nothing changes, you will need to contact David at CM China and see if he can help.
His email address is:

Please let us know what happens.

Alan
 

EEdwards15:
Hi Alan,

Thank you for your quick response. I'm trying to download the suggested parameters, but now I'm running into an entirely different problem. Every time that I plug in the USB, Windows displays an error message that "this device has malfunctioned". In my control panel, it recognizes that the device is connected but doesn't know what it is. It's labeled "Unknown device" and is not associated with any drivers (nor can I seem to figure out HOW to assign it the correct driver...). I uninstalled and re-installed the USB drivers without any luck. I successfully connected and downloaded to this same controller with the same computer yesterday.

I tried multiple USB ports without success and also confirmed the functionality of these ports with other USB devices. The problem seems to be with the controller or the connection to the controller. I tried disconnecting and reconnecting every connection from the USB port to the controller connector, but nothing has changed. Have you seen this malfunction before? Do you have any suggestions on how to resolve this issue? I'd really appreciate your help!

Thanks in advance!
EE

Bikemad:
If you are plugging in the USB plug while the other end is connected to the controller try disconnecting the lead from the controller first and see if it can recognise the USB device on its own.

If the device is recognised correctly, try opening the programming software and selecting the COM port before connecting to the controller and clicking on the connect icon.

If it doesn't recognise the USB device on its own, the problem is either the USB device or the computer/Windows.

If you normally leave your computer in hibernate or sleep mode, try shutting it down completely and then restarting it to see if it helps.
If that doesn't make any difference, try plugging the USB programming cable into another PC or laptop to see if it is still unrecognised.

If another PC won't recognise the USB lead either, it is probably the USB lead itself causing the problem, unless the Program lead for the VEC range of controller uses a different chip to the Magic Pie and Smart Pie vector controller programming cables.

Alan
 

Nuxland:
Hey

I think your problem is that power supply is only 15A.
My 10kw motor uses 15A when it is turning freely, but when it starts to turn, it uses a lot more.
Use batterys.

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