[mohanjude]

All the above suggestions are very helpful. This is a Lehner so I think it is 2 Poles?

I intially tried the Delta configuration by attaching 2 leads each to adjacent connectors (yields 984 odd KV). Then I changed it to Y by attaching only 3 leads from the speedo and connecting the remaining 3 connectors as a star (yields 580 odd KV)

Remember the motor is now on the bench. I am holding the shaft with my hand. I think what Neil said is true - it loses position. What puzzles me is that this motor weighs a ton, is as big as a beer can and yet at low rpm I can stall it with my bare fingers. The dead band thing could be a issue. What concerned me is that I switched to my Schulze 40.160 from a BK elektronics 36.150 (rated 150 amps and rated 42V). I switched because the truck was running fine on this controller until it decided to catch fire while I was trying to move from standstill. I wasn't pushing the controller or doing high speed runs. In fact I had less than 2 mins on this controller. This was a very expensive 2 minutes as the controller cost me several hundred Euros. I am wondering if the controller caught fire because the rotor was 'locked' in position and was drawing AMPS +++ .

The Schulze controller is an automatic configuring controller - ie you dont even have the chance of setting the maximum and low position of throttle like standard controller. It simply locks onto neutral. In the BK controller at least you can chose max throttle and full brake positions by taking off the jumper. On the schulze the only options you can change are on a jumper and the only worthwhile options that remain to be changed are timing high /low and gearing high/low. I dont want to touch the 'frequency' DIP switch.

The motor runs freely on the bench. Here is my stupid hypothesis. If say one of the windings in the phases is faulty will it cause the motor to stall at that position or perhaps not feedback to the controller?

I am thinking if say for example once the motor has momentum can say 2 of 3 the phases compensate due to the inertia of the rotor? A bit like a misfiring cylinder in a car engine will cause the engine to turn over but lack power / torque?

I have never managed to stop a shaft of a brushless motor with my fingers and I am really miffed that I can do this with the biggest 10KW brushless motor that I have owned.

I can pair the motor back with another BK controller that I have but I dont really want to toast it in case there is a problem with the motor. Is there a simple way of checking say resistance etc

Mohan