Re. Case 1:
Check the Hall sensor voltages while they are plugged into the controller rather than a separate 5V power supply.
If you cannot access the metal pins of the connector when connected you may have to use a steel needle or pin to pierce the insulation of the wires to check the voltages.
I suspect they will then switch between 0 and 2.8V, which is probably sufficient to allow the controller to operate correctly even though it is still slightly lower than I would have expected.
I have just tested a similar Hall sensor on a 5V supply and the maximum signal voltage output was only ~3V without a pull up resistor in the circuit, and that was with a neodymium magnet physically touching against the side of the Hall sensor.
Out of curiosity, I increased the supply voltage right up to 10V to see if it affected the signal voltage output, but it stayed exactly the same
(~3V max.)I am not convinced that the Hall sensors are faulty. If they are regularly switching high and low
4 times per revolution of the motor (even if it is just 0V, 1.5V, 0V, 1.5V, 0V, 1.5V, 0V, 1.5V when not connected to the controller) I would say that they are probably working correctly.
However, if the voltage of any Hall sensor does not switch high and low, this could indicate a faulty Hall sensor, but the chances of two different sets of Hall sensors both having one or more [/i]faulty sensors on a new motor is highly unlikely.
Re. Case 2:
Measure on throttle connection
GND and Green = - 4.18 V
GND and Red = 0.88 V
Measure on throttle connection with disconnected hall connection
GND and Green = 0 V
GND and Red = 5.18 V
Something is definitely wrong here, as I don't see how you could have a negative voltage (-4.18V) in relation to ground.
Try measuring this again with your black meter probe on the battery - connection and see what readings you have on the Red, Green and Black throttle wires, as it looks like you may have a faulty throttle ground connection.
I would expect to see 0V between battery
- and both the the black throttle wire and the black Hall sensor wire.
I would concentrate your efforts on finding out why the voltage readings are so different on the throttle wires when the Hall sensors are plugged in, as I would not expect the Hall sensors being connected or disconnected to noticeably affect the throttle voltages.
If the voltages are rechecked with everything connected correctly and they are still as above
(GND and Green = -4.18V and GND and Red = 0.88V) then I would suspect a problem with either the wiring connections between the throttle and the controller, or the controller itself.
You need to eliminate the obvious things first, and that negative voltage reading on the throttle signal wire does not seem right to me.
Alan
