self destructing bike

[shemozzle999]

I put the new sensors in, and wired up a new cable, and went to try it out when there was an almighty fizzle and then everything died. I discovered that a fuse in the battery had blown. so I replaced the fuse and it happened again. I assume this means a blown controller? If much more like this happens I think I'll cry!

I am afraid that you will have to strip the bike down again and go slowly through some tests to find what is shorting out the battery.

First thing to do is unplug the battery and not connect again until you have cleared the fault.
Remove all the all the connectors going from the controller to the bike.
Post some images so that we can see the controller and it's connector wiring
You then need to use a multimeter and measure the resistance of the two pins of controller that was supplying the battery feed.

 

[gillettadam]

the restistance starts high and shoots down to 0, on the first test, on the 2nd and third it was just 0. these are some pictures. I also tested all the wiring for shorts, and nothing has conductivity with anything else, except one of the hall sensor wires shows a certain level of conductivity with one of the others. this is my controller.

 

[gillettadam]

forgot to say this is when nothing is connected to the controller that it settles at 0 ohms

edit: it is also 0 ohms when everything is attached at measuring at the battery input plug

 

[shemozzle999]

With everything disconnected what is the resistance reading you get when you meter across the thick black and red wire that normally connect to the battery?

 

[gillettadam]

0 Ohms between the 2 leads

 

[shemozzle999]

I think that unless you know someone who can fix it, it is the source of the problem and will need to be replaced.
You can have a quick look inside for signs of damage and post a picture.
You will need to know the battery voltage and power rating of the motor to purchase a new one.

 

[shemozzle999]

The controller looks non-standard as it also has to power you bikes lights, maybe you could have a word with Thomsons and see if they could do a part exchange with your old one.

Thompson Euro Tourer Electric Bike [Euro Tourer] - £499.99 : Thompsons Online, The UK&#8217s Leading supplier of Graded Goods

 

[banbury frank]

Hi sounds like you have blown some mosfets That is the black devises fixed to the heat sink you probably have 6 you need to change all 6 to do this you need specialist desoldering tools

Frank

 

[gillettadam]

Thanks for the replys, I've been quoted in the region of 50 pounds!!!! Though the Thompson service team are excellent. I've stripped out the controller and found the 6 mosfets. Not being an electrical whizz, but being fairly competent with a soldering iron and such, would it be a good idea to try and repair the old controller with new mofsets, or had I better start saving up? The mosfets read on them:

IRF 3205
IXR 410k Where X is had to discern, may be an ohm symbol
2Y 7J

 

[shemozzle999]

Could you post some images of the stripped controller Adam.

Remove them one at a time and check with the multimeter to see if the short circuit is cleared across the red and black wires.
Number them up with a felt pen 1 to 6 so you know where they came from and make a sketch of the board showing their positions.

Replacements are available on ebay:

Transistor IRF3205 | eBay

 

[gillettadam]

Here are some images, once the short circuit stops, do I stop removing mosfets?

 

[banbury frank]

Hi For what they cost replaces all 6 they have had a shock and can fail later

don't forget to replace all the insulation washers in the mosfet fixing holes

Frank

 

[gillettadam]

Alright, thanks. I will try and obtain some from 'the bay' before I start doing anything.