cboy said:
One of the grounds on the ground buss is from my auxiliary 12 volt battery.
This is sort of a red flag...
Ideally, an EV 12V aux system should be isolated from the traction battery. Sometimes for smaller (low voltage) vehicles this is not done because isolated DC converters are hard to come by inexpensively, but with a separate battery there is no reason to violate this isolation strategy.
If the 12v aux system shares a common GND with the traction battery then the 12V aux system should not use chassis ground. This is a de facto legacy wiring practice for gassers that should not be followed for lighting or any 12V accessory in this common ground situation. Even if there is no common GND with the traction battery, keeping the chassis neutral is arguably desirable in part because it renders many common chassis shorting failures benign instead of catastrophic.
- If your chassis has a live ground, then it may possibly be that your driver motor has a phase short to the stator which is making its way though the stator, to axle, through the swing arm bearings, to chassis ground, to the 12V aux system, and finally to the common traction battery GND to semi-short that controller phase. With your revised wiring the controllers may be seeing a high phase current and shutting down. Such a motor phase short to stator is clearly undesirable but has no operational effect with an isolated ground - not so in the chassis/common ground case. Other possible wiring phase shorts could have similar effects.
Checking the controller blinking LED error code may give a hint as to why they are shutting down - and may possibly reveal a 'phase wiring' error code which would support the shorted phase idea.
cboy said:
If I disconnect the ground from that [auxiliary 12 volt battery] battery then the wheels will operate....
This seems a plain indicator that you have a traction/aux 12V ground issue. Even if you do not have a live chassis ground you clearly have issues with unwanted traction current finding its way though your accessory wiring.
At this point, I would defer mapping out your wiring for analysis. Instead take the time to separate the 12V aux system from your traction system in all respects. With isolated grounds, it becomes optional to eliminate a live 12v chassis ground if that is presently in place. This will get the 12v system out of the picture and the need for a lot of wiring analysis will go away. From your report above this will go directly to remedying your immediate controller issue regardless of whether the cause is a phase short as postulated. If problems persist, the traction system will be simplified and wiring diagrams, etc will not be as complex.
If things get working, it would be good to then investigate possible phase shorts, etc, but without the common ground, the matter may not materially interfere with operation and you at least will have the option of addressing it or not (i.e external wiring or inside motor).
So - some suppositions here, but maybe there is something in the post that will pan out....