Big Bear - Motor Gone?

[saneagle]

There's a bike repairer just half a mile from us who has done some conversions.
I might ask him to install the new components.
Is insulation tape okay for those blue, green and yellow connections?

Heat-shrink tube is a lot better. I'd put two layers on just to be sure.

 

[stever1957]

Thanks saneagle

 

[stever1957]

I just remembered that my wife's old ebike would have had the same display as mine, and it did.
I tried it, but with the same result - no power, error code 30.
So, I wait for the (almost) new controller.

 

[stever1957]

Parcel from Andy just arrived.

 

[stever1957]

Bike all good again.

Thanks everyone!

 

[saneagle]

Bike all good again.

Thanks everyone!

So, can you confirm what caused the original problem? Were the bullet connectors melted enough to touch? Was it a loose bullet that caused it to over-heat or was it the motor connector not in far enough? I'm pretty sure that your blown MOSFET was a consequence of one of those problems, not the cause.

Going up hills too slowly under full power can also cause the wires to melt and/or the MOSFETs to blow directly.

For anybody else, if your motor becomes intermittent or misfires, you must never try to give it full power because that will blow one or more of the MOSFETs in the controller. When it cuts out, it's a natural reaction to give more throttle or keep pedalling, but that's fatal for the controller.

 

[stever1957]

I spoke too soon.

I now have no pedal assist, but the throttle takes it up to 20.5mph

?

 

[saneagle]

I spoke too soon.

I now have no pedal assist, but the throttle takes it up to 20.5mph

?

As long as the throttle works, no harm will come when you ride the bike.

Possibilities:
1. The pedal sensor isn't turning properly.
2. Bad connection.
3. Wires in the wrong sequence to match each side of the connector.
4. Controller has wrong setting for type of sensor
5. Controller setting has switched off the pedal sensor
6. Controller works with opposite rotating sensor - works when you pedal backwards.

Which type of pedal sensor and connector do you have?

 

[stever1957]

As long as the throttle works, no harm will come when you ride the bike.

Possibilities:
1. The pedal sensor isn't turning properly.
2. Bad connection.
3. Wires in the wrong sequence to match each side of the connector.
4. Controller has wrong setting for type of sensor
5. Controller setting has switched off the pedal sensor
6. Controller works with opposite rotating sensor - works when you pedal backwards.

Which type of pedal sensor and connector do you have?

The sensor and everything are just as they were when all was fine.

there are a few wires/connectors that have no corresponding matches coming out of the controller. eg one with red, black and white wires from controller compartment, the closest from the controller has red, black and yellow.

What I really need is a colour diagram, or even just written details telling me what to connect to what.

 

[Woosh]

What I really need is a colour diagram, or even just written details telling me what to connect to what.

Send Andy a picture and mark the wires you need to know, he'll tell you.

 

[stever1957]

It'll be like photographing a Spaghetti Bolognese, but I'll probably give it a go.

 

[stever1957]

Andy and I are having a fascinating bit of correspondence about red/black/blue > red/black/white and white > black/grey.

The result being that I have throttle/no pedal assist/no speedometer!

Roll on tomorrow,

 

[saneagle]

Red black and white is nearly always speed sensor, though the same colours can be used for throttle. I'd bet that red, black and blue is the throttle. You didn't answer my previous question!

 

[Woosh]

If you could post pictures here, I may be able to help. First, check the motor cable connector. Does it have 3 pins or 6 or 9 pins? Next, does your bike have a spoke magnet on the rear wheel?
Once I know that, I can tell you which wires go where.

 

[stever1957]

Red black and white is nearly always speed sensor, though the same colours can be used for throttle. I'd bet that red, black and blue is the throttle. You didn't answer my previous question!

Do you mean "Which type of pedal sensor and connector do you have? "
If so, I don't know.
Sorry.

 

[stever1957]

If you could post pictures here, I may be able to help. First, check the motor cable connector. Does it have 3 pins or 6 or 9 pins? Next, does your bike have a spoke magnet on the rear wheel?
Once I know that, I can tell you which wires go where.

I'll go and check now.

 

[stever1957]

If you could post pictures here, I may be able to help. First, check the motor cable connector. Does it have 3 pins or 6 or 9 pins? Next, does your bike have a spoke magnet on the rear wheel?
Once I know that, I can tell you which wires go where.

It's six pins and there is no spoke magnet.

 

[Woosh]

6-pin connector: 3 large pins are the phase wires, 3 small pins are connected to the internal speed sensor. Leave the speed sensor unplugged for now.
Follow the pedal sensor cable from the bottom bracket to the controller box. It has 3-pin female connector. On the controller side, the corresponding connector looks like this:

Connect the pedal sensor.
The pedal sensor has a red LED on it. If you turn the crank, the LED should flash.
Switch on the bike, check that pedelec function is working.
Let me know the result.

 

[Woosh]

Connecting the speed sensor:
If you manage to get the pedal sensor to work, the next step is to connect the speed sensor.
Follow the motor cable to the controller box. The speed sensor is connected to a 3-pin male JST connector which needs to be connected to this connector:

speed sensor connector, controller side:

 

[stever1957]

Okay,

I sent Andy a pic.
You sent me two pics.
Andy sent me a pic.

I'm working it all out now and will go back to the bike in the morning.

Many thanks!