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    #16
    per the blog: Some users report a very faint click when they hit the throttle which is the power cut out as the battery shorts to ground from the blown mosfets. The only solution to this problem is replacing the controller
    In so many ways Bafang's BBS02 750W drive unit is a dream come true. Almost anyone with very little technical know how can order a drive kit and 48v-52v battery pack and have it installed and running on almost any bike with 2-3 hours of work. Any other mid-drive ebike kit is going to take a…

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      #17
      Originally posted by max_volt View Post
      per the blog: Some users report a very faint click when they hit the throttle which is the power cut out as the battery shorts to ground from the blown mosfets. The only solution to this problem is replacing the controller
      Thank you MV. It really sounds like the controller went out (mosfets). Is there any way to tell by looking at it (serial numbers?) if my controller is the newer 3077 with 9 mosfets like the seller claimed when purchased?

      Because it went out without any abuse, I'm wondering if I got what I paid for...
      MOVING BACK TO PEDAL...
      2020 Banshee Paradox V3 1x11 (pedal)
      2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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        #18
        Honestly Rider, no. I think you may be in uncharted territory, at least for me! Good luck though, and keep us posted, I am very interested in your findings!

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          #19
          Okay the seller wants me to send the controller to China (at my cost), they will "repair" it and send it back for $25 return shipping...

          First off, can these even be opened up and repaired? The attached picture looks like it is pretty much a solid state construction within all that grey stuff. If I remove those two screws can I see inside to make a repair?

          All this controller "repair" nonsense seems like a waste of time. I offered the seller $50 (my cost to ship it each way) and asked them to simply send out a new controller under warranty. That way they will be $25 ahead (assuming $25 is their really return shipping cost) and not have to mess with repairing anything. That is much more efficient for both of us. Waiting for an answer now...

          MOVING BACK TO PEDAL...
          2020 Banshee Paradox V3 1x11 (pedal)
          2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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            #20
            BTW, I was at the Harley Davidson dealer recently to pick up a relative dropping off his bike and noted their excellent accessary displays. They have all their seat offered covered with leather that has "DEMO" stamped all over it, as well as, wind screens and pipes, also stamped all over with the word "DEMO" in bright orange. How cool is that?

            You can try any of their accessories out in "DEMO" form before purchase. That way you know if you like it before ordering in the color you want.

            This is just what we DIY Bafang BBS## users need at a co-op facility to diagnose problems, so you order the correct broke part. We can always dream about things that make life easier. ;-)
            MOVING BACK TO PEDAL...
            2020 Banshee Paradox V3 1x11 (pedal)
            2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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              #21
              Removed the controller using the Luna sticky thread video. All the connections stayed in tact and were connected properly to begin with. Anyone know of a ebike shop in Orange County, CA that might have a good loose controller that I can connect to verify this one is bad?
              MOVING BACK TO PEDAL...
              2020 Banshee Paradox V3 1x11 (pedal)
              2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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                #22
                Look in the builder for hire section. Several in your area. Luna would also check it for you and sell you a new one as well.

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                  #23
                  The China seller insists I ship the bad one to them for "repair." I've never heard of anyone repairing a BBS## controller, they simply replace them.

                  I mat hit Luna up on my next drive through LA to confirm this one is bad before sending it off.

                  Q: CAN BBS## CONTROLLERS BE DISASSEMBLED AND REPAIRED?
                  MOVING BACK TO PEDAL...
                  2020 Banshee Paradox V3 1x11 (pedal)
                  2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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                    #24
                    Not easily. If you remove the two small screws and gently pry upward around the edges the circuit board can be freed from the housing. You would then need to remove the grey potting material very carefully to expose all of the board components. At that point you could replace your FETs, IF that's the problem. If not your kind of stuck unless you want to reverse engineer the whole thing, as Bafang keeps the circuit schematic quite secret. Even if you had a schematic diagram of the circuit, you have to be top notch at soldering as most of the circuit uses micro components that are easily damaged by hand soldering. My suggestion is to go ahead and buy another controller. I keep one as a spare, along with a display, throttle and main cable, and it has been a valuable tool in diagnosing problems. I did think of a couple of things:
                    Do you use a gear sensor? If so unplug it. With the controller hooked up to the motor and a display, throttle and battery hooked up (doesn't need to be on bike), when you hit the throttle do you get a power indication on the display? If you do the FETs are OK, and you may have bad phase hall sensors. Had this happen on a Cyclone 3k that suffered from 'heat soak'.

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                      #25
                      Just for a point of reference there is a BBS02 controller listed on eBay for $109. But it would be a shame to buy that and then find out it was your hall effects inside the motor.
                      Robert

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                        #26
                        Originally posted by Rider View Post
                        The China seller insists I ship the bad one to them for "repair." I've never heard of anyone repairing a BBS## controller, they simply replace them.

                        I mat hit Luna up on my next drive through LA to confirm this one is bad before sending it off.

                        Q: CAN BBS## CONTROLLERS BE DISASSEMBLED AND REPAIRED?
                        I thought you had 2 BBS02s. One for each of your builds. I am so paranoid about being without an Ebike that I have a BBSHD, BBS02, and an edge 1500 all working on bikes. The two hub motors I have though was just to see what the other style of propulsion is like.
                        Last edited by calfee20; 11-30-2017, 05:57 AM.

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                        • Rider
                          Rider commented
                          Editing a comment
                          My eBikes are just adult toys and not used for daily transportation. I couldn't survive without a car anywhere. Right now both my eBikes have the motors removed. I am in the process of setting up a 29er Adventure eMTB now that this motor in the eCruiser broke. The eCruiser is back to a simple Coaster 3 speed again. I took it for an enjoyable pedal only ride yesterday evening. I also have a MY1018 mid-drive project in the works to try out that motor as a throttle only hill climb assist full suspension MTB trail rig. Still need parts to complete that one. My RockShox 27.5 TK 30 Gold forks sold, so I'm back on track to finish that one off. If the Soma B-Side frame doesn't sell within the few weeks, I'll put the Exotic Carbon Disc 46.5 fork on it and make it slightly more street speed oriented, but would prefer to buy a new Soma Juice frame with the sale funds and have a 27.5+/29er frame to play with. The good thing is, I always have at least one pedal bike to ride. That keeps me satisfied and in shape. ;-)

                        • calfee20
                          calfee20 commented
                          Editing a comment
                          I have to have one running all the time. I have a car and a pickup and when the weather is nice they just sit. Of course I use the pickup to transport a bike to a distant bike path. LOL

                        #27
                        Yes, I do have two BBS02B motors that are identical. I was hoping I could diagnose this problem without taking apart my good working motor to test it with a known good controller, but I was unable to find a local shop that could help me. This morning I reluctantly took the controller off my known good motor and put it on the bad one. Walla! It works perfectly.

                        * * * CONFIRMED THE CONTROLLER IS BAD * * *

                        This is good and bad. This motor has the new 3077 controller with 9 mosfets and it crapped out after 800 miles without abuse. The China retailer is insisting I send the bad one to them for "repair" and have to ship using China Post with a $10 value. AFAIK that means USPS "Registered Mail" or "Express Mail" at crazy prices to get it handed off to China Post WITH FULL TRACKING. Plus they want $25 return shipping to be paid by me as well.

                        I haven't priced shipping yet, but years ago I had to return a very small $65 phone watch and it cost me $35 with tracking from the USPS. Then the retailer claimed they never got it, even though I had a clear tracking record from point to point. In the end I lost $100 instead of just $65 if I simply threw it in the trash and walked away...

                        A BBS02B 750W 48V controller is heavier and larger than that little watch. If it ends up at $50 or above. plus $25 return shipping, I'll be into a new "free warranty" controller for $75, when I can buy one here for $100 and be done with it. I find it hard to believe the retailer didn't take my offer of $50 and just send a new controller. They still claim they are going to "repair" it.

                        I need this question answered:

                        CAN A CONTROLLER BE REPAIRED? IF SO, DOES ANYONE HAVE A LINK SHOWING DISASSEMBLY?
                        MOVING BACK TO PEDAL...
                        2020 Banshee Paradox V3 1x11 (pedal)
                        2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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                          #28
                          Okay, I found this DIY controller mosfets repair post:

                          https://electricbike-blog.com/bbs02-controller-mods/

                          That looks like a lot of work, but if you can put in better mosfets then maybe it's worth trying...

                          I also found this video in which the rider hits his motor hard and apparently blows his controller. Not sure why that would blow a controller?

                          https://www.youtube.com/watch?v=FVeoqoZloHo

                          The interesting thing here is he hooks up a different controller and it runs his BBS02! I didn't know you can do that.

                          So, can a "controller-less" BBS02B have a simple throttle hooked up to it and run it like a MY1018? If so, then maybe this motor will become a simple throttle only electric motor if my MY1018 project works out.
                          MOVING BACK TO PEDAL...
                          2020 Banshee Paradox V3 1x11 (pedal)
                          2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

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                            #29
                            That is a great link but that seems like a lot of work to replace the FETs. I would try to get a deal on a new controller. I don't think you can run any 3 phase motors without some type of controller. The controller is necessary to sequence the coils in the motor. Pulses are created based on rotor angle and velocity. I think most 3 phase controllers work similarly so you can change out the connectors to use a different controller if you know what you are doing or have the schematics.
                            Robert

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                              #30
                              When I saw the problems you were having with the S-A no turn washers I thought you might be riding a little aggressively. Now I am not being critical but before you put it back together you might want to install a temperature sensor.

                              I have pushed my BBSHD a couple of times to see what it could do and when I touched it with my leg I thought I had burned myself. So if we can get them that hot we can burn them out.

                              You could also install an external controller but that is not cost effective.

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