HBL2360 Short Detected

6 years 2 months ago #29529701 by bennyt
Hi all. I am running dual HBL2360 Controllers to 4 motors for an electric vehicle, I am only in initial wiring and testing stages and have only recently fired up the controllers/motors to test (no wheels, just motors), there is no load on the motors at all, so I haven't drawn above 5A per channel.

Currently they have an identical PC configuration (as attached). With analogue throttle control wired to each controller (throttle ground and +5v are only wired to one controller). Currently operating in Open Loop Mode, however will probably change to Torque Mode once I have completed testing. The main Vmot and Ground are connected to a common 48V battery pack (with contactor, and main/individual fuses in place). The Power Control and Ground are connected to a common 12V supply which is being converted from the same 48V battery pack. With an ignition switch, switching to ground to power off the controllers.

Now, one of my controllers runs its motors fine, the other detects a short during initial throttling (can vary slightly, sometimes more throttle, sometime less). Changing the short detection sensitivity levels just makes it last a little longer before detecting the short. Upon testing wiring and inspecting there is no physical short, and it only affects Channel 1, and the motor/wiring are not at fault as I have switched and tested these. I also successfully switched the controller positions in my circuit to check if the main wiring/circuit is at fault, the controller still detects a short on the same Channel 1 in either wiring configuration while the other controller functions fine.

Therefore, in conclusion, it seems it must be the controller? Any ideas if something internal may be faulty? Or what the controller would be detecting? Am I missing something?

Let me know if you need any more information. Any help would be very much appreciated! I want to start driving this thing!

Cheers,
Ben

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File Name: Controller...1830.zip
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6 years 1 month ago #29529703 by TechSupport
Replied by TechSupport on topic HBL2360 Short Detected
If you are using a contactor switch on the vmot line, are you seeing any voltage spike occur when you flip the switch on active? Voltage spikes can damage the output stage.

If you have a volt meter, disconnect everything from the controller.

Take the volt meter and check to see if there are any signs of continuity from the ground wire across each of your channel 1 UVW wires. Then do the same from the VMOT(red wire). If a short is seen, then the damage is definitely on the output stage.

Please confirm.

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6 years 1 month ago #29529705 by bennyt
Replied by bennyt on topic HBL2360 Short Detected
Yes I have a contactor switch with precharge resistor on Vmot the line. I'm not sure how I would detect a voltage spike when switching the contactor so I am unsure. However it is both controllers powered from this one contactor.

I have tested the controllers with a voltmeter across the UVW wires and ground/Vmot separately. Generally I would hear a short beep across the Vmot wire and all 1/2 UVW wires, and then nothing across ground and all 1/2 UVW wires. Same on both controllers, however a little inconsistent as sometimes I would hear a short beep between ground and 1/2 UVW wires also on each controller, also across Ground and Vmot a short beep could be heard.

I hope that helps!

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6 years 1 month ago #29529707 by TechSupport
Replied by TechSupport on topic HBL2360 Short Detected
The short beep is normal. If the beep were to stay active and not stop would mean a short.

If you could, go into the run tab of Roborun+. On the bottom right corner, there is a section called "Channel". Set up the following channels to be queried.

Motor command 1
Motor power 1
Battery 1 Amps
Motor 1 Amps

Then slowly move the top slider in the middle of the browser to either the right or left. While doing so, keep an eye on the status light at the top of browser. When the short comes on, send the motor command back to 0. Then do the same in the other direction and then send the motor command to 0.

At the bottom of the browser, there is a "save" button. Click on "Save, and save the text file. Compress it into a zipped folder and upload here so I can then take a look at the data.

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6 years 1 month ago #29529709 by bennyt
Replied by bennyt on topic HBL2360 Short Detected
Sure thing, thanks for your help so far, please find 3 tests in the zip below. Definitely shorts in reverse quicker than forwards. I tested starting with the opposite direction also.

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File Name: SKI001-Cha...8-28.zip
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6 years 1 month ago #29529710 by TechSupport
Replied by TechSupport on topic HBL2360 Short Detected
I will take a look in the morning. thanks.

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6 years 1 month ago #29529712 by TechSupport
Replied by TechSupport on topic HBL2360 Short Detected
It looks bad.

Please send us an email to This email address is being protected from spambots. You need JavaScript enabled to view it. and request for an RMA number. If this controller was purchased in the last 90 days, it will be covered under warranty. Please provide the reason for return as damaged output. Someone in customer service will then get in touch with you.

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6 years 1 month ago #29529713 by bennyt
Replied by bennyt on topic HBL2360 Short Detected
Bummer. I actually got these in September last year, I've had one running for around 3 months no problems and just fired up the faulty one for the first time in the last week.

Ill start the process and see where we end up. Thanks for your help anyway!

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6 years 1 month ago - 6 years 1 month ago #29529714 by TechSupport
Replied by TechSupport on topic HBL2360 Short Detected
We do offer a repair program if you are interested.

If this is a feasible option for you, then send us an email to customer service for an RMA repair order. We can then quote you a repair price and shipping costs.

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6 years 1 month ago #29529715 by bennyt
Replied by bennyt on topic HBL2360 Short Detected
Good to know thanks. Ill wait for a response on my email last week and see what feedback I get.

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