GM 10kW with VEC500 rumbles and grumbles, but does not spin.

[Orgoglio]

Howdy.  Name's Fred.  I have golden motor 10kw with a vec500 (and the outboard boat throttle option) that I bought a couple years ago as a means to covert a small john boat to electric power.  System came with no instructions, but I have it wired per the intrawebs and your helpful forum.  I get a green light and happy controller beep when powered on...but advancing the throttle in either forward or reverse results in motor twitches and vibrations without rotation.  Presumably this is a phase issue?  Apologies in advance for my ignorance and gratitude in advance for any help.

[Bikemad]

Hi Fred andto the forum.

If all six of your Phase wires are connected as shown below they should not be causing the problem:


Click image to see full size version.

Have you tried swapping over to the spare Hall Sensor connector to see if it makes any difference?

When you move the throttle and the motor twitches, does the controller emit an error code (series of beeps/flashes)?

With the battery power turned off, can you physically rotate the motor shaft at least a complete turn by hand?

Is the motor actually bolted onto a temporary or permanent mounting plate or is it just being tested loose on the bench/floor etc.?

Are the voltage settings in the controller correct for the battery voltage being used, and is the battery at least 50% charged?

I'm not sure what else to say at this stage.

Alan
 

[Orgoglio]

Thank you for your reply.  It is wired as per the diagram.  Ive swapped hall sensors without change.  No error code upon throttle manipulation in either forward or reverse (it draws current and amps, as would be expected--but just grumbles and vibrates).  Motor shaft rotates (not freely...presumably a result of permanent magnets?...but is not too difficult to spin).  Motor is not bolted to anything...just sitting on a bench.  Battery is at 72% and 53 volts.  I have thus far been unable to connect to the PI-800 software--device doesnt show up on the com port and gives me an error when I try to connect.  The controller gives me 16 beeps when connected to USB.  It could be that i'm using a windows emulation software (going to rectify that shortly).  Thanks again for your help.

[Orgoglio]

...shouldve said motor shaft rotates by hand.

[Orgoglio]

Welp...I am at a loss.  Finally got the software connected and as far as I can tell, it seems to be set up correctly (although I will submit, that's not very far).  I havent checked the voltage on the individual halls sensors as yet (seems unlikely that 2 redundant sets of hall sensors would be bad)...but I will undertake that next.  I have posted a video--as my vocabulary is inadequate to describe what is happening.  Thanks again for your time.

https://youtube.com/shorts/Uci7faR77K4

[Orgoglio]

Fixed.  Figured i'd post and update in case anyone else runs into this problem.  Swapped the blue and yellow phase wires...presumably wired incorrectly from the factory?  Now runs properly with blue connected to "U" and yellow connected to "W".

[Bikemad]

Thanks for the update, I'm so relieved that you've been able to locate and rectify this unexpected problem.

I have just been studying the video, and the Yellow, Green and Blue Phase wires definitely appear to be in their correct positions on the motor casing, so it looks like they must have somehow been connected incorrectly internally on both stators. 

I apologize for the delayed response as I have been away for a few days and have only just finished celebrating a very delayed "Christmas Day" with a large family gathering at home today.

Alan
 

[Orgoglio]

You have my gratitude for your forum.  Excellent resource.  Hope your holidays went well!