#32489

I have installed an electric drive on my sailboat using a kit supplied by Electric Drive Engineering in Western Australia. It uses a Motenergy 10kw motor in conjunction with a Sevcon Gen 4 size 4 controller and Opus display. I have adapted the system to output to my original sail drive. The system is only used to get in and out of the morning pen and has clocked up about 10 hours use over the last 10 months or so. It has worked flawlessly until now. A couple of weeks ago, I went out for a sail and on the way out everything was fine, but about 4 hours later when returning to the pen, it refused to function.

The line contactor is working fine with 48V either side when actuated.

The Sevcon controller is not showing any error messages with a solid green indicator light and I am not getting any error info from the opus display.

I have removed the coupling between the motor and gearbox and both rotate freely when not powered up, however when I power the system up and select forward/reverse and apply throttle, the output shaft of the motor locks completely with the amps ramping up considerably. With no throttle but in gear I can also detect noise from within the motor indicating it is attempting to turn at about 2 or 3 second intervals.

The unit came with the controller and display set up by the supplier.

I have checked all the connections and am getting the full voltage at the controller.

Hoping someone might have some advice...?

#32490

Have you checked the 35-pin connector? Is the SEVCON GEN4 controller correctly connected and locked?

?

Can you connect the controller to the CAN bus via an IXXAT USB-to-CAN interface?

With the DVTC software, it is "easier" to debug the controller...

Do you have the wiring of your system ? For example, if there is an input that lock the motor or set a freewheeling mode...

Sincerely.

Thierry

#32491

I have similar motor and Sevcon. Your issue is new to me, but when I have issues, I unplug all connections and clean them with a small diamond bit I have for my Dremel. Usually this fixes my issues.?

?

#32492

Hi Tim,

I had the same problem a couple of years back with my Sevcon/Motenergy combo (purchased from Thunderstruck).? It all worked great when I benched it and then it stopped working later on (the motor would vibrate a bit but not spin).? The problem ended up being the controller board in the engine (the Motenergy one costs about $30 US).? When Thunderstruck shipped me a new board it worked fine and I haven't had a problem since.

The controller board is in the back of the Motenergy motor, under a small screwed in panel.? I may have a picture from some previous emails that I can dig up.

#32493

It would be surprising if a locked up system was the result of poor contact, but for something as simple as cleaning connections I recommend Deoxit D5.? I have a small (5 oz) aerosol can.? The stuff has been effective in my case.
[-tv]

#32494

I had the same symptoms as jeffsschwartz@...?2 years ago (motor didn't turn but vibrated slightly on activation of the throttle) and it was the RMB29 encoder module located on the back of the motor. Easy to change and all good after. I bought two so that I had a spare in case it happens again

#32495

开云体育

Interesting to learn that the angular position sensor boards have this level of failure rate.

On balance, my 20yr old ETEK brush motor (on 4^th set of brushes) setup doesn’t look so bad even today with so many seasoned brushless alternatives.

I did have an Alltrax AXE controller fail this summer (after 20 years), but that was probably my fault.

I replaced it with a used one bought on Ebay (Alltrax NPX) which didn’t deliver close to the battery voltage let alone its rated full power.? Thankfully, Alltrax agreed to reflash the memory in the controller and changed the throttle type to ITS (inductive throttle sensor) for me and it’s been working like a charm since.? No idea why but even while it acknowledged full throttle it would only output about ? battery voltage to the load. ?That used controller was a boat-anchor if it weren’t for Alltrax doing this for me.

?

Show quoted text

From: [email protected] [mailto:[email protected]] On Behalf Of jeffsschwartz@...
Sent: Tuesday, November 7, 2023 8:46 AM
To: [email protected]
Subject: Re: [electricboats] sevcon controlled electric drive does not rotate

?

Hi Tim,

I had the same problem a couple of years back with my Sevcon/Motenergy combo (purchased from Thunderstruck).? It all worked great when I benched it and then it stopped working later on (the motor would vibrate a bit but not spin).? The problem ended up being the controller board in the engine (the Motenergy one costs about $30 US).? When Thunderstruck shipped me a new board it worked fine and I haven't had a problem since.

The controller board is in the back of the Motenergy motor, under a small screwed in panel.? I may have a picture from some previous emails that I can dig up.

#32496

Yea 9 times out of 10 its the encoder (position sensor) that fails and if the motor gets they will get wet and fail. Always good to have a spare on board. If you install the replacement carefully you can usually get away with not needed to reprogram the controller.?

?For this reason I'm a fan of sensor less motors on boats. There is no advantage to have a sensored motor thats only a? prop.??

Matt Foley?

Sunlight Conversions

Perpetual Energy, LLC

201-914-0466

ABYC Certified Marine?

Electrical Technician?

On Tuesday, November 7, 2023 at 01:59:00 PM EST, Myles Twete <matwete@...> wrote:

Interesting to learn that the angular position sensor boards have this level of failure rate.

On balance, my 20yr old ETEK brush motor (on 4^th set of brushes) setup doesn’t look so bad even today with so many seasoned brushless alternatives.

I did have an Alltrax AXE controller fail this summer (after 20 years), but that was probably my fault.

I replaced it with a used one bought on Ebay (Alltrax NPX) which didn’t deliver close to the battery voltage let alone its rated full power.? Thankfully, Alltrax agreed to reflash the memory in the controller and changed the throttle type to ITS (inductive throttle sensor) for me and it’s been working like a charm since.? No idea why but even while it acknowledged full throttle it would only output about ? battery voltage to the load. ?That used controller was a boat-anchor if it weren’t for Alltrax doing this for me.

?

Show quoted text

From: [email protected] [mailto:[email protected]] On Behalf Of jeffsschwartz@...
Sent: Tuesday, November 7, 2023 8:46 AM
To: [email protected]
Subject: Re: [electricboats] sevcon controlled electric drive does not rotate

?

Hi Tim,

I had the same problem a couple of years back with my Sevcon/Motenergy combo (purchased from Thunderstruck).? It all worked great when I benched it and then it stopped working later on (the motor would vibrate a bit but not spin).? The problem ended up being the controller board in the engine (the Motenergy one costs about $30 US).? When Thunderstruck shipped me a new board it worked fine and I haven't had a problem since.

The controller board is in the back of the Motenergy motor, under a small screwed in panel.? I may have a picture from some previous emails that I can dig up.

#32497

开云体育

is there a way to test the board on the motor?

TIM HOOPER
DIRECTOR
____
?
t?? 03 9690 2788
f?? 03 9690 2899
w?acumendesign.com.au
?
?
6/132 Bank St
South Melbourne
Victoria 3205
?
acumen

#32498

Yes !

?

You need to power the board: with the controller switched on, or disconnect the sensor and use an external +5V supply.

?

Then, with an oscilloscope and by turning the motor, you can see the sine and cosine waves on the oscilloscope screen.

(Take a look at :??)

?

Thierry

#32499

The RMB29 datasheet says it has conformal coating.? For more challenging environments I would add a Silicon coating like Dow Corning 3-1765 or 3-1953 avoiding excess buildup on on the IC body

#32513

Hey everyone, thanks so much for your feedback!
On my motor what I’m assuming is the board is located as part of a fully encapsulated unit that flush fits in the back and attached with the 3 cross head screws…?
I’m going to have a crack at testing it this weekend…
Btw, picture of installation attached…

#32516

That's it!? Once you take the 3 screws off you'll see the board mounted underneath with a bunch of gunk holding it in place.

#32523

The motor itself?is not?sealed well enough, and in this saildrive orgintion water can collect on the top of the motor and seep in .

The 4 screws that hold the encoder down can also short out the board, it helps to put fiber washers under these . Sometimes just removing the screws fixes the encoder problem.

Brian D. HAll


	ThunderStruck Motors, LLC 2985 Dutton Ave. Ste 3 Santa Rosa, CA 95407 Tel: (707) 578-7973 Fax: (707) 581-1860