Controller box

[Budgie1]

Hello everyone. I've just upgraded to a Wings ebike Alpine 13 with the 1000w off-road kit. The bike looks great, it uses a Dolphin battery case on the down tube and a controller bag attached to the top tube. Personally I don't much like the look of a controller bag also worry it might attract the wrong sort of people thinking someone has left their bike luggage behind. I've googled for a few days looking for a plastic controller case to fit probably again on top tube - these boxes seem to look modern and in my opinion add a more fitted feel to the bike. My problem is I just can't find one to accommodate the controller - its in an aluminium box measuring 170mm length, 85mm width and height 60mm.

So my question is - if I removed the circuit board from its aluminium housing so its now smaller, is this okay to fit into a plastic controller case or do I need to keep it inside its metal case to help act as a heatsink?

Many thanks.

 

[Deleted member 4366]

It needs a heatsink of some sort.

 

[Budgie1]

It needs a heatsink of some sort.

Thanks very much for the instant reply. So I will keep the controller in its aluminium housing and keep a look out for something large enough to accommodate it. Maybe I will grow to like it with time

 

[Deleted member 4366]

Can we see a photo of what you have?

 

[Budgie1]

Can we see a photo of what you have?

I'll take one tonight when home and post it.

 

[Budgie1]

Work got a bit mental so I've only just had a chance to upload some photos. Overall I'm very pleased with the bike - it is allowing me to commute to work on decent days (well dry) in a suit and not arriving in a puddle. It's about 11 miles each way, with mostly climbing (sometimes very steeply) on the way home. I did order a couple of plastic controller boxes, neither fitted so I've decided to cut my losses and just ordered a better quality frame bag.
A couple of observations so far:

1. The brakes seem poor. The Incline 13 gets a good review and it seems a decent spec for its price point. Some reviews do mention the pads need to be run in hard so I will try that or change the pads. The extra weight is possibly clouding my opinion as well.
2. Gearing - factory spec on rear Shimano HG200 - 9 Speed - 11-34t with 3 cogs on front. On downhills I would like a bit more gearing to reduce my pedalling cadence so I don't look quite so silly. Interested if everyone has changed their gearing maybe the opinion is it isn't needed on an e-bike
3. Considering changing the knobbly tyres to something smoother in hope it will extend the battery life a bit all other things being equal
4. Electrical issue - last week on way home (with fully charged battery) when I reached the top of the steep hill the battery flat warning came on and I was on my own. This was only after 5 miles and I'd already proven 22 doable with charge remaining. I assumed as I was tired I'd used more juice and luckily that was the last hill so I cruised home pedal power only (actually not too bad so another plus for bike). However when I attached the charger the light did not go red and the battery would not charge. Wing ebikes quickly dispatched a new charger which did not make a difference. Green light meant to turn red when charging. I checked the 30amp fuse on battery it was fine. So the vendor reckoned it must be the battery and to his credit sent a new battery next day delivery (arriving today). He mentioned a battery failure very rare so I hope I've just been unlucky. Customer service has been excellent though.
5. When changing my controller bag I am left with 1 connection shown in photo I just cannot split. Any suggestions as to the wizardy needed to split this would be gratefully received.

 

[Alan Quay]

3. Schwalbe Big Apples will work really well on there.

4. I don't know what cells are in that battery, but they would have to be pretty expensive ones to have a high enough rating for a 25A controller. I'd be concerned that the battery is not up to the job, and that the BMS has cut it out due to voltage sag/over current.

5. They should just pull apart.

 

[Budgie1]

3. Schwalbe Big Apples will work really well on there.

4. I don't know what cells are in that battery, but they would have to be pretty expensive ones to have a high enough rating for a 25A controller. I'd be concerned that the battery is not up to the job, and that the BMS has cut it out due to voltage sag/over current.

5. They should just pull apart.

Thanks Alan. I will check out those tyres! On Wing ebikes website it states all the batteries have Samsung cells which was one of the reasons I went for that seller. I'll keep in touch with the seller once he gets the original battery back as I'm interested to understand what happened to it.

I will try again to pull apart the leads. There is another join closer to the hub with the same connector so I might try there first. I did pull really hard, obviously not hard enough but I wanted to avoid causing any damage in case the connector needed a twist or something.

 

[Alan Quay]

Thanks Alan. I will check out those tyres! On Wing ebikes website it states all the batteries have Samsung cells which was one of the reasons I went for that seller. I'll keep in touch with the seller once he gets the original battery back as I'm interested to understand what happened to it.

I will try again to pull apart the leads. There is another join closer to the hub with the same connector so I might try there first. I did pull really hard, obviously not hard enough but I wanted to avoid causing any damage in case the connector needed a twist or something.

It depends on exactly which samsung cells, and how many. It also depends on how the BMS is set up.

 

[Alan Quay]

Thanks Alan. I will check out those tyres! On Wing ebikes website it states all the batteries have Samsung cells which was one of the reasons I went for that seller. I'll keep in touch with the seller once he gets the original battery back as I'm interested to understand what happened to it.

I will try again to pull apart the leads. There is another join closer to the hub with the same connector so I might try there first. I did pull really hard, obviously not hard enough but I wanted to avoid causing any damage in case the connector needed a twist or something.

On the subject of tyres, I have a 26" x 2.0 big apple spare (Almost new, I prefer the bigger 2.35's, and you might too).

I'd happily swap it for your redundant controller box if it the right size.....

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