8 flashes on eZee kit how to solve/prevent

[Christian Schade]

Hi - I have read the threads on this problem but I am not sure it solved my issue:
I own a brand new recumbent trike equipped with an eZee conversion kit in ebike mode only.

A couple of days ago I suddenly couldn't start my trike in the morning (ruined my whole day, it did). The notorious 8 flashes on the diagnostic light indicated Hall sensor fault. The previous forum messages on this subject however suggest that this might be a moisture problem.

Well, I do live in Denmark and it almost rains as much here as in the UK - however, the trike is parked out of the rain at night and I have had it indoors for at least 24 hours now and tried drying it with a hairdryer. No luck.

So now the question is:
1) What part of the kit should I attempt to open and clean up, if any?
2) Assuming that this is a humidity issue, how can I prevent this from recurring during the coming long, cold and VERY wet winter?

Any feed back and friendly suggestions would be greatly appreciated.

regards
Christian

 

[flecc]

Hello Christian, welcome to the forum.

The indicated Hall sensor problem is sometimes a problem of loss of connection in the leads from the motor's Hall sensors to the controller. This is usually at the connectors which sit in the wiring below the battery platform on most models, though the location could be a little different on your kit. The cable from the motor carries three thick current wires which normally have "bullet" connectors and five thin wires which are the Hall sensor connections. Those five thin wires are routed through a plastic five way connector and moisture in there can cause contamination resulting in the lost connection.

If you locate that connector, it's the larger of the two similar types in that position, the other being a three way, you can unwrap it's insulation and then try unplugging and replugging it a few times to clean it. If that was the problem that action remakes the connections and the motor will run. I've experienced this same problem on my eZee bikes. If you can obtain a switch/contact cleaner fluid aerosol from an electronics supplier, a little of that sprayed on the connections will lubricate and protect them. Obviously reinsulate the connector thoroughly afterwards.

The problem can also be with moisture in the controller, but this normally only happens when water actually runs in, as on an eZee Quando folder laid on its side when wet. Of course this is very unlikely on your trike and I've never known just condensation cause this. Drying the controller out can take a long time due to the restricted air inside it's small box and limited ventilation, I've found it tends to need both some hot air flow and a dehumidifier in an enclosed space for drying to occur in a short period.

 

[Cyclezee]

Hi Christian,

Glad you have joined the forum.

Sorry to hear about your problem. I agree with Flecc, it is more than likely a connection problem, so I would follow his advice.
Flecc has being riding eZee bikes for several years and if you were not already aware, he is our number one expert on the subject of electric bikes.

If yours is one of the later controllers as shown below, it is unlikely to be moisture in there because they are absolutely water tight.

Hope you get it fixed and are soon on the road.

 

[Christian Schade]

Hi Folks - I found he solution to the above problem, and it was neither a faulty sensor - nor humidity.

When the conversion kit was mounted at the factory, apparently a set of connectors from the controller to the motor had been packed inside a small connection box that I had taken to be a part of the controller. That seems to be an extra bit on the conversion set.

After flooding everything with contact cleaner and going over all the connectors and looking for broken wires and trying to remove any water with a blowdryer, I lost patience, and taking a risk, I opened the black plastic box next to the controller box and found that a connector had physically disconnected, pure and simple. Phew.

It probably happened when I messed around with centering the main frame of the trike, which can be adjusted around the length axis.

Taking Flecc's advice, I have now cleaned the box and all other connectors with contact cleaner and sealed them all with self-amalgamating tape (my new favorite thing). I also taped the connector inside the box to prevent a recurrence.

Regards,
Christian, back on the road, crossing my fingers and getting ready for torrential rain.

 

[banbury frank]

Hi Christian,
Can we have some photos I am sure other forum members will be very interested in you recumbent trike

Perhaps a new Thread

Frank

 

[flecc]

Pleased to hear that you found the problem in that extra connector box Christian, the usual rule applied, the more parts, the more to go wrong!

Agreed on the self-amalgamating tape, nothing better for this purpose.

 

[Cyclezee]

Hi Christian,
Firstly, I am glad you fixed the problem.
When you say connectors in a connection box, I take it you mean Anderson and JST? These are quite a tight fit and care is needed when assembling. On my trike, I did not use the box, just made the connections, put heat-shrink around them and sealed the ends with cable ties. It is watertight and would never need to be taken appart unless you removed the kit.

Hi Folks - I found he solution to the above problem, and it was neither a faulty sensor - nor humidity.

When the conversion kit was mounted at the factory, apparently a set of connectors from the controller to the motor had been packed inside a small connection box that I had taken to be a part of the controller. That seems to be an extra bit on the conversion set.

After flooding everything with contact cleaner and going over all the connectors and looking for broken wires and trying to remove any water with a blowdryer, I lost patience, and taking a risk, I opened the black plastic box next to the controller box and found that a connector had physically disconnected, pure and simple. Phew.

It probably happened when I messed around with centering the main frame of the trike, which can be adjusted around the length axis.

Taking Flecc's advice, I have now cleaned the box and all other connectors with contact cleaner and sealed them all with self-amalgamating tape (my new favorite thing). I also taped the connector inside the box to prevent a recurrence.

Regards,
Christian, back on the road, crossing my fingers and getting ready for torrential rain.