1000W BLDC Motor Overcurrent & Hall Fault

Hi all,
We recently installed an ATO 1000W 24V BLDC motor with an ATO-BD50 controller and 80:1 worm gearbox. We're getting two kinds of blinking error codes and need help understanding what they mean and how to resolve them.

Issue 1: 2 Red Blinks (Overcurrent Alarm)
Does this indicate overcurrent on the motor output side or the controller's power input side?
It seems to occur under load or during sudden changes. We tried adjusting the current protection knob but are unsure of what exactly it controls.

Issue 2: 3 Red Blinks (Hall Sensor Fault)
What does this indicate? We've checked the wiring and grounding visually, but aren’t sure how to fully diagnose it.

Other Questions: Is there a way to clear the alarm without power cycling the controller? Does the "PC" knob adjust the overcurrent threshold on the motor or supply side?

Need Advice! Thanks in advance!

Odette wrote:Odette, we had the same controller. If your motor has high inertia (especially with an 80:1 gearbox), try soft-starting or ramping up gradually. Sudden start/stop caused overcurrent on ours, too. The PC knob helped a bit, but it’s not a full fix if the mechanical load is jerky.

Odette wrote:Maybe you can check the voltage drop across each Hall wire while slowly turning the motor shaft. If one doesn’t toggle between ~0V and ~5V, the Hall sensor might be dead. We had one that only failed under load due to a crimped wire.

Odette wrote:Odette,
The 2-blink alarm is from overcurrent on the motor side, not the power supply input. Possible causes:
1. Sudden load shifts (e.g., braking)
2. Motor cable issues or winding failure
3. Incorrect UVW/Hall wiring
The 3-blink Hall fault suggests:
1. A short or open in the Hall sensor wires
2. Crossed wiring between Hall and UVW signals
Unfortunately, there is no reset function besides power cycling. The PC knob adjusts the motor-side current protection threshold — turning it up will allow a higher peak current before tripping.

Thanks, everyone!
We’re going to inspect the Hall lines more carefully, test toggling under rotation. Will report back if the issue persists.