Dying (Dead) Controller

Positive discussion on ebikes and pedal assist bicycles

Dying (Dead) Controller

Postby Hamster » Mon May 13, 2013 2:07 pm

Guys,

I fear that my controller is about to die, I’ve had one die before and the current symptoms are very similar. The controllers that I’m currently using seem to be only lasting around 2,000 kms which is obviously seriously inadequate. I'll check out tonight what I've currently got and perhaps post a picture of it.

What I need is a controller for a 36 Volt, 250W brushless motor. The only connections are to the battery, motor and throttle. Any suggestions on what would be a robust & rugged replacement and where I could source it from.
It would not be at all strange if history came to the conclusion that the perfection of the bicycle was the greatest achievement of the nineteenth century.
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by BNA » Thu May 16, 2013 9:35 am

BNA
 

Re: Dying (Dead) Controller

Postby Hamster » Thu May 16, 2013 9:35 am

I’ve done a few sums on the controller that I believe is causing my current loss of power. If my sums are correct then when the battery voltage has dropped to its safe minimum of 31.5V I would have been pulling through the controller around 8 1/2 amps. This is well above its rated capacity of 6A so I suspect that I’ve had it operating above its safe capacity for a considerable time :shock: .

I gave a replacement ordered from Solar Bike :) which has a significantly higher capacity than the old one. So (fingers crossed) once I receive it all should be good and the new one will have a significantly longer life :D .
It would not be at all strange if history came to the conclusion that the perfection of the bicycle was the greatest achievement of the nineteenth century.
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Re: Dying (Dead) Controller

Postby Hamster » Sat May 25, 2013 3:35 pm

I've replaced the controller with one I bought from Solar Bike. All seems good again without any sudden loss of power.
It would not be at all strange if history came to the conclusion that the perfection of the bicycle was the greatest achievement of the nineteenth century.
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Re: Dying (Dead) Controller

Postby cachexian » Fri May 31, 2013 11:17 pm

Great. Let us know how it goes.

C
Scott Sub 40 with 200W, 36v Ezee geared front hub motor
and...
Trek Madonne 3.1 driven by left leg and right leg
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Re: Dying (Dead) Controller

Postby Hamster » Sun Sep 01, 2013 7:13 am

The two previous controllers each died at 2,000 kms. The replacement from Solarbike is still operating at 2,600 kms so fingers, toes and eyes all crossed and done while touching wood the problem might be solved.

Hoping that I haven't jinxed myself.
It would not be at all strange if history came to the conclusion that the perfection of the bicycle was the greatest achievement of the nineteenth century.
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Re: Dying (Dead) Controller

Postby Hamster » Wed Oct 23, 2013 8:06 am

Seems that I had jinxed myself as my third controller appears to by dying but after 4,250 kms. At least now I believe that I know the reason - I'm cooking them. The next one will have a higher amperage rating 22A rather than the previous 12A and 17A but more importantly I'll place it where it will get a good flow of air across the heat exchangers.
It would not be at all strange if history came to the conclusion that the perfection of the bicycle was the greatest achievement of the nineteenth century.
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Re: Dying (Dead) Controller

Postby cachexian » Wed Oct 23, 2013 12:50 pm

Sorry to hear that.
Where were you mounting the controller?

C
Scott Sub 40 with 200W, 36v Ezee geared front hub motor
and...
Trek Madonne 3.1 driven by left leg and right leg
cachexian
 
Posts: 121
Joined: Sun Jul 25, 2010 10:39 pm


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