XB-600 Controller Wire harness

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polecat
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Last seen: 4 months 2 days ago
Joined: Tuesday, June 7, 2011 - 11:56
Points: 29
XB-600 Controller Wire harness

I recently replaced my motor hall sensors on an XB-600. Re-installed the motor and performed a test. The motor operated for a short time, then failed, but intermittently. I checked the throttle: 0.82V-4.98V (depending upon the throttle position: good), brake switches: one is failing (left side), but I disconnected the brake switch harness to bypass brake switch: good, checked the voltage off the batteries to the controller: 61.5v (5 batteries in series: all good), and then checked the voltage at the motor wire harness at the controller: small black and red hall sensor power supply: 2.75V varying to 4.75V (strange readings). I then checked the voltage across the returning hall sensor wires (green, blue and yellow): 5.72V (fixed while I rotate the rear wheel)......then after a while, suddenly the hall sensors begin to respond properly: 0.08V-5.72V (depending on wheel position). I noticed the hall sensors operated properly when the hall sensor power supply provided 4.75V, but failed to function when that supplied voltage dropped to 2.75V. I proceeded to unplug the controller hall sensor wire harness and tested the voltage directly off the controller: small black and red hall sensor supply: 6.75V, three returning hall sensor wires (green, blue, yellow): 5.72V. Why am I reading a voltage of 2.75V intermittently across the motor hall sensor power supply when the controller is supplying a constant 6.75V? Is it a hall sensor wire harness contact problem or is the problem with the controller itself? Any suggestions would be greatly appreciated.

mopedbrainy
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Last seen: 1 year 9 months ago
Joined: Tuesday, June 10, 2008 - 19:06
Points: 122
Re: XB-600 Controller Wire harness

After trading controller it was necessary to shed off throttle harness, which included two grey connectors for the half/full speed.That, and the brake wires within the main harness contain some small in line diodes wrapped in heat shrinkers .They might be the culprits. Brake wire also grey. Good luck.

mopedbrainy
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Last seen: 1 year 9 months ago
Joined: Tuesday, June 10, 2008 - 19:06
Points: 122
Re: XB-600 Controller Wire harness

After trading controller it was necessary to shed off throttle harness, which included two grey connectors for the half/full speed.That, and the brake wires within the main harness contain some small in line diodes wrapped in heat shrinkers .They might be the culprits. Brake wire also grey. Good luck.Left side brake (meaning rear wheel) uses diodes to kind of lock rear wheel-magnetic brake?. Front brake only cuts off current.

polecat
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Last seen: 4 months 2 days ago
Joined: Tuesday, June 7, 2011 - 11:56
Points: 29
Re: XB-600 Controller Wire harness

Turns out, the problem is the controller. I've run a wire bypass across the hall sensor controller power supply harness (voltage drops to 2.75V; no function to motor). I then wired in an external 5.75V power supply (1.2V AA rechargeables X 4; motor functions normally). I've placed the external power supply under the seat (temp solution until I replace the controller).

Now that the motor function normally, I noticed that my motor brake no longer engages when I press down on the right side brake lever. Any ideas why this is the case?

polecat
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Last seen: 4 months 2 days ago
Joined: Tuesday, June 7, 2011 - 11:56
Points: 29
Re: XB-600 Controller Wire harness

O.K. I purchased a new controller from Ebay (a generic 1500W self-study/sensor/sensorless controller). I've installed it on the XB-600. I noticed, the original controller destroyed the hall sensors, before it went to 'controller heaven' (all three hall sensors show 4.28V fixed; no change). Now that the new controller is installed, I was hoping it would operate the motor in sensorless mode. Am I correct to assume, the new controller requires the hall sensors, to learn the firing sequence, the first time? Is there any way I can operate this controller, without having to remove my motor and replace the hall effect sensors? Any input, would be greatly appreciated.

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