Problems with BAC-0501 controller

[Stevebequik]

Hi GM team.

New member, first time posting and first brushless project

BAC-0501 controller help.

I have a new BAC-0501 controller connected to a 48v 1800w unite brushless motor.
on application of throttle, motor barks ars is cogging vilently.
Give the bike a pushstart and then runs fine.
So this indicates the controller is working in sensorless mode.
I have tried all 36 phase/hall sensor combinations, and all combinations gave exactly the same sesults.
disconnecting the hall plug also gives the same result.

I have tested the 5v supply to the Halls, and the 'switching' of the halls. This checked out OK.

Can I connect a buzzer to this controller to see if I get the 2 beeps if running sensorless? if so, what connections?
Could my motor be a 60degree motor when controller is setup for 120 degrees? if so how do I check change this?
what else could make this controller run sensorless when there are functioning halls sensors connected?

Thanks for any help.
Steve

[Bikemad]

Hi Steve andto the forum.

I presume that you checked the Hall sensor signals from the back of the controller connector while it was plugged in and powered up, in which case the signals are reaching the controller.
Are you sure that each of the Hall sensor signals alternated correctly between ~0V and ~4.5V as the wheel was moved very slowly?
(As demonstrated in this video)

I'm not sure if the BAC-0501 controller has a horn facility like the BAC-281P controllers have, but I would assume it uses pins X1 and X2 if it does.
Try placing a voltmeter across these connectors to see if there are any detectable pulses.

If the motor required the 60 degrees phase angle instead of 120 degrees, you would need the USB programing lead and software to change this setting.

Usually it is a Hall sensor fault that causes sensorless mode to engage.

Alan
 

[Stevebequik]

Thanks Alan,

I pulled the motor apart to try and figure out if it may of been a 60 degree motor and found one of the halls sensors wiring damaged.
Was able to repair and now all is working.

Steve