VEC 300 - Led and output voltages died, not motor move- but still USB conection

[GuilleMeca]

Hi, Thanks for open this space for new users.

We have a Golden motor 5Kw BDLC motor with a VEC 300 controller, the analog signal is generated by a microcontrolled board and this setup worked fine until today for many tests.

However, today we put a stop emergency button in the e-lock line, by error, we send an analog signal to the driver (Analog and ground only) in the pedal port when the e-lock are open.

Also, we try to activate reverse and brake signal using electromechanical and solid state relays, but this no work well, this is the other change.

After that, the driver can't generate the output voltages in the pedal, brake and reverse port, for this reason the motor can't move. We verify the connection and cable continuity a lot of times. However, we can connect the USB programming cable normally, view and change the parameters.

What is the possible reason for that? Exist any procedure to come back the driver board to the factory state? What can we do?

We will be truly grateful for your help.

Sincerely

Guillermo Sánchez
Mechatronic Engineer

[Bikemad]

Hi Guillermo andto the forum.

If there is no voltage output, I would check to make sure that you still have a +5v feed going to the throttle and motor Hall sensors.

If you powered the microcontroller and the relays from the controller's +5V supply, you may have overloaded the internal voltage regulator, as it is only meant to supply very low current (milliamps) for the Hall sensors.  The windings of an electromechanical relay would probably try to draw too much current. 
If the +5V feed has also stopped working, the 5V regulator inside the controller could have been damaged, but you may be able to supply it externally using a suitable DC/DC step down converter.

It might be a good idea to test it first with 3 x 1.5V batteries connected in series just to see if it will work. 

Regarding the use of solid state relays, if you were using relays designed to switch AC loads, they may not turn Off again after initially being turned On. This is because they are typically designed to turn Off right in the middle of the AC sine wave when the voltage/load is at zero. If you have a DC voltage on the output it will never be zero and the relay may be unable to turn Off. 

Alan