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Troubleshooting

Troubleshooting Resources
Wiring & Connector Issues Experience shows that this is the most common failure encountered by LEVs.
EMI/RFI ("noise") Diagnosing and fixing issues surrounding corrupted data signals.
Troubleshooting @Grin The web's BEST single point resource when your LEV project needs some TLC. Brought to you by the world's best ebike shop, GRIN Technologies at ebikes.ca.

 

 

 

 

 

 

Wiring & Connector Issues

One of the most common connectors used in the LEV world for power wires/cables is the Anderson PowerPole (R) ("Anderson") connector. In the lighter weight series (15-45 amps), these connectors are very convenient and flexible in their use, and are generally reliable - if used correctly.

Shown below is an example of how these Anderson connectors can fail (the three yellow connectors). The black connectors show the correctly positioned inner terminals.
bogies_skyride_rv-120_phase_wire_powerpole_connectors_bad_closeup_photo

The same yellow connectors shown above now have the cable terminals repaired and correctly installed into the Anderson housings. Note that the 'hooks' of the terminals crimped onto the cables, and inserted into the housings, are inserted so that they're completely over the top of the housings'spring plate. When inserting the terminal into the housing, keep pushing until you hear a distinctive 'click' generated by the terminal slipping over the spring.
bogies_skyride_rv-120_phase_wire_powerpole_connectors_good_closeup_photo

 

 

 

Hall Sensor testing

There are any number of ways to determine whether the Hall sensors embedded in a BLDC motor are working correctly. One of the easiest is the use of an "ebike tester" which tests phase wires, Hall sensors, and standard throttles. For phase and Hall functions, this type of tester will work with both the motor and/or the controller. This generic chinese tester was purchased several years ago for less than $20 (testers available today will probably be available with English labels). In this example, the motor's hall sensors were all functioning correctly, evidenced by their lighting up 3 LED's sequentially while the motor was rotated by hand.
troubleshooting_ebike_hall-phase-throttle_tester_photo

 

 

 

 

 

 

EMI/RFI

Both electro-mechanical interference ("EMI") and radio-frequency interference ("RFI") can be pernicious gremlins that will completely kill an otherwise perfectly functioning LEV.

We originally ran into this issue when implementing our strain gage based methods used to provide electric assistance and control for LEVs, including the INA circuit board.

In this example from the Endless-Sphere forum, one member describes how a very specific type of EMI (current induced into the bike's steel frame from a running motor) prevented his bottom-bracket based torque and cadence sensor's data from being accurately read.
Although he does not specifically identify the motor as the primary cause, in our experience it is the actual spinning motor, solidly attached to the bike's frame, which is the actual culprit.

 

 

 

 

 

 

 

 

 

 

 

 

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