BBS02-B Power Assist Stopped Working

[Rider]

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

Yes, I agree. But if you end up with a "better" controller using the quality mosfets that aren't in the BBS02B controller, then you end up with something that should be more reliable.

Running it without the stock Bafang BBS02B controller is interesting. I understand you have to have another external controller hooked up. IMHO that seems like something worth looking into.

[Rider]

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.

No, this motor nor my other BBS02B haven't been "abused" at all. Neither one has ever got hot to the touch; I put my hand on both all the time to check heat. The problems with the SA washers are related to several factors: smaller axle in a larger slot, wrong type of anti-rotation washer for a vertical drop, axle nuts "unknowingly" working loose due to constant reversing torque that only loosens and never tightens, 750-1000W with pedaling being more than human power bicycle parts are designed for, etc...

Most of my SA anti-rotation washer problems were on the Soma B-Side. The Electra had SA 5spd auto-upshifting problem for about the first 500 miles, but seemd to get loosened up after that. This BBS02B controller failed at 800 miles of normal use. There is no reason for it to fail other than it being defective. It certainly wasn't heat related, although it could be that the mosfets aren't good enough to handle normal use electrical heat threw them (?).

I'm surprised that there is no way to tell if this controller really is the newer 3077 model with 9 mosfets by the serial number. At least no one has stated it can be. It might be worth opening it up to see if that is determinable by looking at the mosfets themselves (?).

[Rider]

It's looking like returning the controller to China for a warranty replacement is cost prohibitive. You have to use USPS Express Mail to get a tracking number to the destination. That will cost $62US. The seller wants another $25US for return shipping, so I'd be into the FREE WARRANTY REPLACEMENT for $85US and any future warranty would still be China based. I'm not willing to send that much for what could possibly be another defective one.

The external controller on the MY1018 brushed motor was only ~$15. Paying $100 here in the US with a US warranty makes more sense than spending $85 for a China one. Researching external controllers also seems like an interesting learning experience as well.

There was another poster here that had the same issue (referenced early in this thread). I have to wonder if there is a bad batch of controllers out there on the BBS02B's or if someone in China decided to use up an old batch of the weaker ones to cut costs. Unfortunately manufacturers over there are certainly known to do that kind of thing...

[Robert62]

I think its going to be hard to figure out how to wire an external controller. Not that it can't be done but it would be a research project. My controllers use 3 phase power wires (easy part) and 5 "control" wires. I assume one is power and one is ground. The other 3 may be outputs from hall sensors that feed back to the controller? I'm pretty sure someone here could educate us if they see this thread.
I'm confused about the guy in the video who hooked up just the phase wires from the Lebowski and it seemed to work. Is it always that simple? Why does my hub motor have 5 extra wires?
Robert

[Rider]

I think it really is that simple for a throttle only assist to a simple electric motor. All those other wires are likely for all the sensors that are not needed in a throttle only on/off setup without display like: brake cutoffs, cadence, speed, display stuff, back-pedal, etc... All I can think of is how all the electric motors I played with as a child simply had a variable switch that turned them on and increased power. If it's spring loaded, then power shuts off when you let the switch go.

[Rix Ryds]

You can hook up any brushless controller to the BBS02 or HD. the 5 wires you speak of are the phase hall sensors some controllers need them (sensored), some do not (unsensored). There is no standardized color code for these so it may not work correctly by just matching colors. there is a method for determining what hooks up to what. See attached jpeg. Sensored is more efficient. Be aware that the BBS02 is not a particularly robust motor and if you run it hard you will have problems. If I were you I would just buy a new controller from California Ebikes, about $100 and simple plug and play!

[calfee20]

I think its going to be hard to figure out how to wire an external controller. Not that it can't be done but it would be a research project. My controllers use 3 phase power wires (easy part) and 5 "control" wires. I assume one is power and one is ground. The other 3 may be outputs from hall sensors that feed back to the controller? I'm pretty sure someone here could educate us if they see this thread.
I'm confused about the guy in the video who hooked up just the phase wires from the Lebowski and it seemed to work. Is it always that simple? Why does my hub motor have 5 extra wires?
Robert

ERT has a kit for BBSHDs and just because it is for 72 volts doesn't mean you have to use it. http://electricrt.myshopify.com/coll...pgrade-72v-40a

[commuter ebikes]

If this were me, I would just buy the proper replacement controller from Luna and set the other one aside for spare parts or tinkering. $100 isn't much for a controller. Mine are $299. I can't even afford a spare.

[Rider]

You can hook up any brushless controller to the BBS02 or HD. the 5 wires you speak of are the phase hall sensors some controllers need them (sensored), some do not (unsensored). There is no standardized color code for these so it may not work correctly by just matching colors. there is a method for determining what hooks up to what. See attached jpeg. Sensored is more efficient. Be aware that the BBS02 is not a particularly robust motor and if you run it hard you will have problems. If I were you I would just buy a new controller from California Ebikes, about $100 and simple plug and play!

It looks like the retailer has come around to my way of thinking and is going to work with me by just sending me a new controller without me returning the old one to China. Still have to put out some $$$'s, but less than what I saved buying it from him. Should have this BBS02B up and running soon.

[Rider]

ERT has a kit for BBSHDs and just because it is for 72 volts doesn't mean you have to use it. http://electricrt.myshopify.com/coll...pgrade-72v-40a

HOLY VOLTS BATMAN! It's sold out anyway...

[calfee20]

Remember this is for a BBSHD. I just opened his program and he is feeding 72 volts and 45.8 battery amps with 60.8 phase amps into a BBSHD. You can't believe the out of stock thing because he doesn't keep his web site up very well. An email is needed to confirm what is going on. You should watch some of his videos.

It seems he has fooled with a BBS02 also. Here is a link to his YouTube videos. https://www.youtube.com/user/wavebicycles/videos
Pay attention to his death trike videos.............I am surprised he isn't dead yet.

I have the 12 fett controller he uses on the BBSHD but I am using it on my 1500 edge DD hub Fat Electra right now and I don't have a 72 volt battery...........yet. He sells a 26 amp 72 volt battery that I can fit on that Luna Cargo frame I just got. That should be a hoot.

[Rider]

If this were me, I would just buy the proper replacement controller from Luna and set the other one aside for spare parts or tinkering. $100 isn't much for a controller. Mine are $299. I can't even afford a spare.

That's what I would have done if the seller didn't finally come around. Although I will be putting out a little shipping cash, I now have the old one for "tinkering" like you say. Might be fun to play with and maybe learn something new.

[Rider]

Thank you all for your help with this! I will be back in the saddle soon...

[Robert62]

I'm glad it going to work out (cheaply) for you!
Also RixRydes- that diagram is awesome!!! Am I correct that on the 5 wire connector one is + and one is ground?
BTW, I only ride on uncensored controllers!
Calfee- That dude is CRAZY! I don't expect to see many more videos from him....

Robert

[Rix Ryds]

That's correct. Red is +, black is -, phases are yellow Blue and green. There is also a $20 tool you can buy, think I got mine from EM3EV, that will help you sort out the proper connections. really comes in handy for diagnosing bad phase hall sensors as well!

[Rider]

WHOA! The warranty replacement controller arrived today and it's the 5 wire model. Sweet! It has the shifter cutoff wire at the motor and light wires that run off the main battery. I couldn't be happier. I was going to sell this motor once the new controller arrived, but now I want to keep it for my badly wanted Surly ECR build some day; already have the wheel and tire set for it. I also have a shifter cable cutoff that will plug into that low motor wire leaving the two uppers for the brakes and was hoping to do some guided night rides in Limestone Canyon next year. Have to start looking for a good set of proper voltage lights now.

Anyone know what voltage that wire puts out?

[calfee20]

I asked for that when I ordered my kit but didn't get it.

[Rider]

I couldn't find one either when I ordered my second motor. Didn't even think to ask for it when replacing it. It's probably just what they had in stock and I got lucky.

[mosfetBob]

Hello, first post , Ive just been given two non working Bafang motors. I read the C961 manual. On the BBS02B motor it doesnt run in pedal assist but does run in walk assist mode but doesnt sound smooth. I wondered if this is indicative of anything. I only have a bike frame and no throttle to test. if anyone has links to an electrical connection diagram that would be really appreciated. I wondered if it could be the pedal assist hall effects. Determined to repair . I'll check out the fet replacment vid mentioned earlier. Looking forward to riding E.

[ncmired]

Here's a connector diagram: