Controller phase wire issue

[UrbanPuma]

Hi all,

UPDATE: the indicator is flashing orange and displaying Overload when I sit on the bike and turn the throttle - it judders too. I've just put the battery on charge. Could it be the battery?

My bike lost power recently, then when twisting the throttle the bike juddered and lost all power. The indicator lights were still on and after wheeling it home power returned, but it's not as sprightly as before.

I opened up the controller panel and noticed the phase wires' electrical tape and plastic tubing were fused together and burnt. After removing both, I noticed the yellow connector was loose too.

I have now connected the yellow one tightly and everything works, but my concern is what to cover them with individually so they resist the heat this time. And would this problem affect the power?

Any ideas - would covering them with the items in the picture below be fine?

 

[Andy-Mat]

Hi all,

My bike lost power recently, then when twisting the throttle the bike juddered and lost all power. The indicator lights were still on and after wheeling it home power returned, but it's not as sprightly as before.

I opened up the controller panel and noticed the phase wires' electrical tape and plastic tubing were fused together and burnt. After removing both, I noticed the yellow connector was loose too.

I have now connected the yellow one tightly and everything works, but my concern is what to cover them with individually so they resist the heat this time. And would this problem affect the power?

Any ideas - would covering them with the items in the picture below be fine?

Thats would seem to be a good idea, use far longer pieces so that the ends are tight on the cable, either side of the connector, so as to make more waterproof as well. This will help to prevent corrosion as well.
Two pieces, one over the other, would also press the connector more tightly together I feel...
Look here later for other ideas as well, from other members, then make your choice.
Andy

 

[vfr400]

The heat comes from the connector itself. Many people have had this problem. If it were my bike, I'd cut those horrible bullet connectors off and solder the wires directly to each other, then cover with two layers of your heatshrink tube.

 

[UrbanPuma]

Thank you both. I'll do as you suggest Andy-Mat as it's within my skill range.

Vfr400, my main concern with soldering is whether it would interfere with getting the back wheel on/off as the power cable runs directly to the hub/back wheel. It's something to consider though if all else fails.

 

[Nealh]

Bullets on Phase connections are known to be problematic, heat causes contraction and for the plastic insulation to melt. One can try crimping the female end a tad for a tighter fit and then as you have, use the heat shrink to insulate.
A couple of other options is to solder/fuse the ends directly together to prevent them moving or use an MT60 tri connector.

 

[UrbanPuma]

Thank you Nealh, I have a delivery of MT60 connectors on the way, so will definitely try that if I have any more problems.

 

[UrbanPuma]

I've just put the red and blue heat shrink tubes onto the connectors - all appears fine. Please find picture attached.

 

[Nealh]

Good work.

 

[UrbanPuma]

Good work.

Thanks. I have another problem...could you have a look at the update on my first post at the top please and advise?

 

[Nealh]

The juddering is unlikely a battery fault is your hub sensored ?

 

[UrbanPuma]

The juddering is unlikely a battery fault is your hub sensored ?

I'm not sure, it's a Powacycle Puma:

PowaCycle Electric Bikes | Puma Lithium Polymer Electric Folding Bike Clearance

I put the battery to charge for 4-hours this afternoon and just tried the bike. It's working fine and all lights remain green, so thinking maybe my battery was out of juice?

 

[Nealh]

Looks like I was wrong, glad it is ok now.
I was thinking it may have been a hall issue or wire issue after your phase wires melted.

 

[vfr400]

I'm not sure, it's a Powacycle Puma:

PowaCycle Electric Bikes | Puma Lithium Polymer Electric Folding Bike Clearance

I put the battery to charge for 4-hours this afternoon and just tried the bike. It's working fine and all lights remain green, so thinking maybe my battery was out of juice?

A run down battery wouldn't cause that issue. There's another problem that will probably raise its ugly head sooner or later unless you have a controller with automatic phase and hall configuration that got confused after you disconnected the wires.

 

[UrbanPuma]

A run down battery wouldn't cause that issue. There's another problem that will probably raise its ugly head sooner or later unless you have a controller with automatic phase and hall configuration that got confused after you disconnected the wires.

Ah no Vfr400, the juddering started before I disconnected the wires. I'll check it again tomorrow though. Thanks

 

[UrbanPuma]

Looks like I was wrong, glad it is ok now.
I was thinking it may have been a hall issue or wire issue after your phase wires melted.

Thanks Nealh, I hoped it'd neither of those as I'd be way out of my depth. I'll check again tomorrow just to make sure. Do you think I should charge it again or will those 4-hours be enough?

 

[Nealh]

Use a meter and measure the battery voltage, the battery will have a +/- discharge just poke the meter's probes in each hole and get a reading having set the meter's dial to 200v dc, turn the dial to the left.

 

[Nealh]

I was thinking initially after your phase wire issue that a mosfet may have failed but usually they either work or don't, that is why I said it wasn't a battery issue.
We need to see a nice pic of all the controller connections to see if it is sensored, as vfr has indicated sync may be out and juddering is a sign.

When you repaired the phase wires are you 100% they went back correctly as sometimes colour to colour isn't always the correct sync combo.

 

[UrbanPuma]

I was thinking initially after your phase wire issue that a mosfet may have failed but usually they either work or don't, that is why I said it wasn't a battery issue.
We need to see a nice pic of all the controller connections to see if it is sensored, as vfr has indicated sync may be out and juddering is a sign.

When you repaired the phase wires are you 100% they went back correctly as sometimes colour to colour isn't always the correct sync combo.

Hi Nealh,

Many thanks for your replies. I can check pics from a previous post in 2018 and have a diagram from that time too to help me dismantle and reconnect wires. I'll dig them out and double check. I have been using the bike without any problems for a year since I changed controllers, but did smell burning recently and then experienced these recent issues.

I'll check today and report back.

Thanks!

 

[vfr400]

I have been using the bike for a year since I changed controllers,

The story continues to develop. Maybe it's time to show us what you have. If it has the self-learning wires, I bet they're still connected, so it's trying to relearn every time you switch on.

So this is the second time you've had problems with those bullet connectors!

When I was at school standing in the Headmaster's study he said to me, " There are three types of people: Clever people learn from other people's mistakes; normal people learn from their own mistakes; thick people never learn. Lets hope you're in the middle category because you're clearly not in the first."

Einstein said that you can't solve problems with the thinking that created them in the first place.

 

[UrbanPuma]

Hi Nealh,

Many thanks for your replies. I can check pics from a previous post in 2018 and have a diagram from that time too to help me dismantle and reconnect wires. I'll dig them out and double check. I have been using the bike without any problems for a year since I changed controllers, but did smell burning recently and then experienced these recent issues.

I'll check today and report back.

Thanks!

Hi Nealh,
I checked connections and all wires were put back correctly. There are 8 wires in total connected to the hub motor:
3 phase wires (green, blue & yellow)
and 5 other wires together (green, blue, yellow, black & red).

Then there's 2 cadence sensor wires, 2 battery wires and 4 others ( left & right brake, throttle and front light/LED) and a purple one which wasn't connected originally (kept as is).