HBL2360 Short Detected

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

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!

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.

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!

Good to know thanks. Ill wait for a response on my email last week and see what feedback I get.