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  1. #1

    Need help wiring brushless controller

    As the title says, I need some input on wiring a brushless controller. Actually, I'm changing out one controller for another.
    This is the wiring diagram for the new controller:




    This is the wiring plugged into the existing controller.



    The large red, black and white wires on the right are obviously the motor U, V and W.
    Likewise, the smaller wires on the left are for the Hall sensors and correspond to HU, HV, HW, V+ and Ground.
    The question is, which color is which? Are these things standardized?

    TIA,
    Walt

  2. #2
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    Re: Need help wiring brushless controller

    Typically U-V-W and HU-HV-HW would have matching colors, but it does not seem to be the case with your old driver.

    My wild guess is:
    Black=GND
    Red=Hall sensor V+
    White, yellow, blue=HU, HV, HW (not necessarily in that order).

  3. #3

    Re: Need help wiring brushless controller

    Now my guess would have been quite different.
    I had red, white, yellow pegged as as HU, HV, HW and blue as V+ and black as GND.
    I'd hate to guess wrong and let the smoke out.

  4. #4
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    Re: Need help wiring brushless controller

    Is your old controller working (or at least powering up)? You could try measuring the voltages on those 5 wires. Or you could check the PCB traces and see where they go.

  5. #5

    Re: Need help wiring brushless controller

    I replied to this once. I must have forgot to post it.

    At any rate, I believe you called it from the start.
    Using an ohm meter, I found the red lead goes to the large (ish) cap on the far left. The black lead goes to the three small caps and the white, yellow, blue go to the 810 resistors next to those small caps.
    I think it would be reasonable to assume the white, yellow, blue correspond to the white, black, red on the motor leads.

  6. #6
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    Re: Need help wiring brushless controller

    Glad you got the wiring sorted out, let us know when you get it working.

    What happened with the old controller, did it smoke? What was it based on, the infamous Sanken chip or discrete transistors?

  7. #7

    Re: Need help wiring brushless controller

    Oh, right. That was the reply I forgot to post. The old controller works fine but it's for a sewing machine. Love the motor but the controller is optimized for a sewing machine. No surprise there. Very difficult to get proper PWM speed control out of it.
    There are several solutions to get these controllers working with our stuff. I spent way too much time on those only to find them barely usable.
    I finally decided to cut my losses and get a compatible controller.
    As for whether or not I've got the wiring sorted, well as soon as I get the time and courage, I'll let you know if it was a success or if I've ordered another motor.
    Cheers.

  8. #8
    Super Moderator Al_The_Man's Avatar
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    Re: Need help wiring brushless controller

    I would agree on the hall red & black, as to the hall signals you shouldn't do any damage trying the six combinations, the motor exhibits jerky and obvious wrong motion if the hall combo is wrong.
    Is there any marking on the board in Chinese script?
    Al.
    CNC, Mechatronics Integration and Custom Machine Design

    “Logic will get you from A to B. Imagination will take you everywhere.”
    Albert E.

  9. #9

    Re: Need help wiring brushless controller

    Quote Originally Posted by Al_The_Man View Post
    Is there any marking on the board in Chinese script?
    Al.
    Just on the motor leads. You can see it there by the 201 resistor. I'll get a better closeup if you know someone that can translate.

  10. #10
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    Re: Need help wiring brushless controller

    There is Google Translate app - you point your phone at the hieroglyphs and it shows you something fairly close to English.

  11. #11

    Re: Need help wiring brushless controller

    I don't think knowing the motor leads helps if you still don't know the hall leads.

  12. #12

    Re: Need help wiring brushless controller

    Well, I hit a snag. Take a close look at the actual controller and compare that to the schematic.
    Where the V+ reference for the hall sensors used to be, is now a forward/reverse terminal.



    In a bit of wishful thinking I wired it up anyway hoping that terminal might somehow do double duty. That only made it run backwards. No surprise there.
    I does run open loop way slower that it should. The hall sensor a simply not in the game.
    Got any more suggestions for me?

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