BBSHD controller melt down

[MarkGale68]

I ran this new ebike build for approx. 3 hours, nothing heavy mostly flat pavement, it shut off a few times for no reason I had to stop the bike and power it back up, at times pedal assist would not engage sometimes until I hit the throttle.
When I was adjusting the rear derailleur with walk assist with the bike on a stand it would go into walk assist and then full speed and walk assist again and then it just died with a distinct burned plastic smell.

I'm trying to figure out what could have caused this, battery was charged to 80% when started

Luna Bafang BBSHD
Luna wolf pack v2 52V
500C DISPLAY

[wagonroad]

My BBSHD also suddenly cuts out. I discovered that the speedo and magnet detector has a broken wire that jiggles loose. Apparently, the controller requires speed input to function properly. This $10 item is "out of stock" at Luna Cycle, so my ebike is grounded. Ho, ho, another Chinese donneybrook!

[Tommycat]

I think Bafang has narfed this work around on newer controllers... Sounds like Pax is working to get it back in the firmware. Depends on the age of the controller I guess.
Fingers crossed.

[JPLabs]

Oh, okay, thanks Tommycat.

I'm loving my early controllers more and more. I hope they never die.

The controller programmer community is awesome. It's the sharing of program software, and tuning ability, that makes me love the Bafang BBS platform in the first place. If that goes away, they may drive me away.

I dream of open source firmware, someday........

[AZguy]

+1 - I really like the ability to modify the controller parameters and it's a huge plus for the BBS and like you I'd really dig getting open-source firmware but understand that's most likely a dream

I don't think there is a perfect setup that will work for every person (let alone every bike) and it's awesome to be able to personalize

[JPLabs]

I ran this new ebike build for approx. 3 hours, nothing heavy mostly flat pavement, it shut off a few times for no reason I had to stop the bike and power it back up, at times pedal assist would not engage sometimes until I hit the throttle.
When I was adjusting the rear derailleur with walk assist with the bike on a stand it would go into walk assist and then full speed and walk assist again and then it just died with a distinct burned plastic smell.

I'm trying to figure out what could have caused this, battery was charged to 80% when started

Luna Bafang BBSHD
Luna wolf pack v2 52V
500C DISPLAY

WOW, it sure did! Impressive carnage, there!

Is that a stock controller? It kind of looks like, on the right side, there is a heavy run of solder on the board, like a beefed-up current trace which someone laid more solder on, to increase current capacity. It almost looks like a shunt-modded controller, but if that was under the potting I guess it's factory, or it's some solder that melted and ran during the event. Plausible, too, I think. Just...curious looking.

Did you remove the potting after the 'event' or had it been previously removed?

Is it normal, or Ludicrous version?

I think there was arcing someplace, to make all that soot. Thing is, it wouldn't tend to deposit all over the board like that, if the potting was there, causing me to wonder if the potting was removed before this happened. And if so, why? To beef up the board and increase current?

It almost looks like a modded board, to me, just from the photos, but maybe that's not possible. Maybe they are like that factory, now, Bafang may do that.


You list it as Luna BBSHD. Did you get it right from them, or buy used?

[MarkGale68]

Luna sent out a free replacement controller they did not even charge me for shipping , honestly they only seemed to want to get my bike going again, thank you so much Luna.
I got it all back together took it out for a spin , so far ,so good, no weird behavior like the original, going out this weekend for a few hours will post more

[JPLabs]

That's awesome! Happy riding.