PowerPac Electric Bike Limp Mode Fault

[Deleted member 4366]

I had a feeling that yours would be like that. The 8 leg component could be a microprocessor that translates the hall signal to an analogue one or anything else. IC2 is the actual hall sensor. There's some info here to explain how it works:
http://www.bristolwatch.com/hall_effect/

The main point is that you should have 5v between pins 1 and 2, and pin 3 should go on and off when you bring a N and S pole magnet to it, Can you test that while it's powered up?

If it gets the 5v but doesn't switch, you can replace just the hall sensor, which costs pence. I can give you the spec later. If the hall sensor is OK, but the rest doesn't work, the easiest thing is to get a new KU65 controller plus throttle and PAS from BMSbattery, which should cost about £35. Then you'll have a conventional system that everybody understands.

I don't think you can get a cartridge BB in 90mm, so you should take your BB splined tool back to Halfords and get a couple of replacement caged ball races while you're there.

 

[campbell1987]

Magnet disc has been rubbing the PAS sensor but has not yet worn through, IC2 appears to slightly damaged looking, Here's a close up,

http://tinypic.com/r/k9f91f/8

 

[shemozzle999]

It looks like it has been blown - replacement from here:

http://uk.mouser.com/ProductDetail/Diodes-Incorporated/AH173-PL-A-A/?qs=EJYhozv%2bYpyUN8vu3DMslQ==

 

[Deleted member 4366]

You need to do the measurements above. it could be a different voltage to 5V too.

 

[campbell1987]

Enter Quantity: (Minimum: 2550) << I only need 1...
Also I'm no expert but the numbers on my ic2 is 173 621v which is prety close to the 621-AH173-PL-A-A shemozzle999 posted and it says Operating Supply Voltage 3.3v or 5v or 9v,

I found this AH175-PL-A-B on Ebay

http://www.ebay.co.uk/itm/HALL-SENSOR-LATCH-GRADE-B-3SIP-Part-AH175-PL-A-B-/271226750516?pt=UK_BOI_Electrical_Components_Supplies_ET&hash=item3f265fc634

Does this look like the same component??

 

[shemozzle999]

From the manufacturers data sheet there are two options:

Type A a narrow magnetic band switching device15 to 60 gauss
or
Type B a wide magnetic band switching device 5 to 80 gauss

The one you have found is type B.

Worth a try for a couple of quid.

The important thing is to assemble it the same way round as the original - note the device shape.

 

[campbell1987]

Ok, I've ordered it now so will update post once it arrives and i fit it, Thanks.. ;-)

 

[Deleted member 4366]

Why have you ordered a replacement when you haven't tested the one you've got?

 

[campbell1987]

Cause it looks damaged.. ??

 

[campbell1987]

Can i test this one with a multi meter?

 

[Deleted member 4366]

I told you how to test it:

Power it up and check that you get 5v on pins 1 and 2.If you don't, there's no point in buying a replacement. Then check that pin 3 goes on and off when you pass a magnet over it N then S. If that's OK, then it could be that 8 legged component that's faulty, or anything else.

 

[campbell1987]

Ok so the hall effect sensor made no difference, I get 5v across pin 1 and 2, Pin 3 does go on and off but its very intermittent, doesn't seem to reach 5v either, i only see about half that, Will the KU65 controller plus throttle definitely fix my problem?? If so where would be the best place to buy it from??

 

[Deleted member 4366]

If the hall sensor only reaches 2.5v, it's faulty. A replacement is very cheap, and will probably fix it.

The KU65 will definitely get you going again if you get the throttle and pedal sensor with it. You get then from BMSBattery.com

 

[campbell1987]

Thanks d8veh.... I already tried this (http://www.ebay.co.uk/itm/HALL-SENSOR-LATCH-GRADE-B-3SIP-Part-AH175-PL-A-B-/271226750516?pt=UK_BOI_Electrical_Components_Supplies_ET&hash=item3f265fc634) but still have the same fault, Might just go for the ku65 you mentioned, I was talking to my dad and he'd like to have it as fast as possible without the PAS so he gets full power from hand throttle, Seen a wee guide here for souping them up a bit,

http://www.avdweb.nl/solar-bike/electronics/ku63-motor-controller.html#h1-disabling-pas-pedal-speed-control

Do i need to install the pedelec legalization device?? Will the bike still function without this?

And just to be sure before i order so im not waiting on more parts is this all i need??

http://www.bmsbattery.com/controller/415-hall-sensorsensorless-250watts-brushless-hub-motor-controller.html

 

[Deleted member 4366]

That's the right controller. Get a PAS sensor too. It makes riding much easier. Don't forget to order a throttle too.

You don't need to do any of those modifications, except maybe solder a bit of the shunt for more torque.

 

[campbell1987]

I was planning on bypassing the PAS to get full power from hand throttle if possible so do i still need to buy one?? Also can you recommend a compatible throttle to go with the ku65??

 

[Deleted member 4366]

The throttle will always take precedence over the PAS so you get the best of both. The PAS also gives full power on level 3.

All the BMSB throttles are compatible. You have to look at which one will fit your handlebars. 5he plain half throttle is most likely to fit unless you have twist gears, then you need a plain or switched thumb throttle.

 

[campbell1987]

Ok so think i just found the source of the problem,

http://tinypic.com/r/5osh9x/8

looks a bit of a mess, I've separated all the wires and insulated them all using heat shrink, Only one i couldn't trace was the head lamp bulb power cable, What way do i wire the head light in?

http://tinypic.com/r/jpu4o8/8
http://tinypic.com/r/2dahv9x/8

 

[campbell1987]

I just received all the parts i ordered, Though some connectors are different like the motor connection and also some have wires crossed, as shown is this pic,

http://tinypic.com/r/106alo3/8

Am i ok to splice, solder and heat shrink the wires that haven't got the correct connections and also should i cross the one shown in the pic so each wire connects to the one with the same color,

Also would there be a diagram showing what each wire from the ku65 is for, no paperwork received with the order at all.. ;-)

 

[Deleted member 4366]

Yes just swap over the blue and the yellow pins. If you go to the BMSB listing, there's a "download" tab at the bottom with a wiring pdf.