How To, 50A BBSHD Controller Mod

General Discussion about electric bicycles.
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fechter
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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Dec 06, 2017 9:39 pm

Nice to see the insides. Thanks for posting the picture.

I can't make out the numbers on the chips very well.

What's this one?
BBSHD display board.jpg
BBSHD display board.jpg (148.17 KiB) Viewed 430 times
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E-mil
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Re: How To, 50A BBSHD Controller Mod

Post by E-mil » Dec 07, 2017 6:31 pm

I knew you'd gonna ask about that chip, which definitely looks a buck converter.
Unfortunately I don't have a better or clearer image, not even the original hi-res pic enhances it.

And I'm not going to open it up again now. 😛

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Re: How To, 50A BBSHD Controller Mod

Post by tomjasz » Dec 07, 2017 10:52 pm

E-mil wrote:
Dec 06, 2017 6:00 pm
Well, here's to the rescue, Fechter:

I can detail how to safely break it apart if you wish.. I rubber-glued it together, and it's without problems since.

Please?
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Dec 08, 2017 12:05 am

Which model of display is that?
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Re: How To, 50A BBSHD Controller Mod

Post by E-mil » Dec 08, 2017 9:28 am

The display is the DPC-14 aka C850 .

Here are the pics and description from my memory. Have to say I managed to break a corner of the front glass, but luckily it doesn't affect anything.

Display assembly description:
The display is surrounded by a square removable plastic rim which is held in place with several plastic notches - 3 on the sides, 2 top and bottom. Under this is the edge of the displays' glass, which is not glued but rather sticky tape is used, put between the glass plate and the cabinet's plastic. Important to know is that the flat LCD cable sits in the right side of the display, so you have to be careful not to open this side too wide or cut too deep!

How to open:
The plastic rim is quite easily pried off. Look at the pics for location of latch points.
The difficult part is now the glass. I used a narrow blade/scalpel to carefully work my way around the edges, making sure I didn't press too deep inside. In hindsight it could be a good idea to oil the blade and seal, as the tape tends to stick to the knife. As I found out, the glass is likely made of .. glass. Be careful. Work your way around the edges until it starts to lift.
When glass is lose, open from LEFT side, and dont twist it. Else the flat cable can break.

Inside of the cabinet is the backside of the circuit board visible. It is held in place with some screws IIRC.


Flat cable can be seen inside. Don't open this side any further!
The plastic rim is already removed here. Notice the broke glass corner:
DPC-14 C850-1.jpg
DPC-14 C850-1.jpg (78.65 KiB) Viewed 390 times
Bottom side view:
DPC-14 C850-2.jpg
DPC-14 C850-2.jpg (68.01 KiB) Viewed 390 times
Left bottom side view:
DPC-14 C850-3.jpg
DPC-14 C850-3.jpg (150.12 KiB) Viewed 390 times

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tomjasz
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Re: How To, 50A BBSHD Controller Mod

Post by tomjasz » Dec 08, 2017 1:13 pm

E-mil wrote:
Dec 08, 2017 9:28 am
The display is the DPC-14 aka C850 .

Here are the pics and description from my memory. Have to say I managed to break a corner of the front glass, but luckily it doesn't affect anything.

Thank you!
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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Re: How To, 50A BBSHD Controller Mod

Post by sc5252 » Jan 30, 2018 3:08 am

Excellent thread.

Taken the plunge and ordered new shunts.

Will report back.

Many thanks to all.

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Re: How To, 50A BBSHD Controller Mod

Post by espresso » Feb 09, 2018 11:48 am

This is presumably the modification that Luna does when they supply the BBSHD with the Ludicrous controller?

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Feb 09, 2018 2:57 pm

espresso wrote:
Feb 09, 2018 11:48 am
This is presumably the modification that Luna does when they supply the BBSHD with the Ludicrous controller?
Yes.
"One test is worth a thousand opinions"

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Re: How To, 50A BBSHD Controller Mod

Post by espresso » Feb 10, 2018 10:55 am

fechter wrote:
Feb 09, 2018 2:57 pm
espresso wrote:
Feb 09, 2018 11:48 am
This is presumably the modification that Luna does when they supply the BBSHD with the Ludicrous controller?
Yes.
Does anyone besides Luna sell this commercially?

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Re: How To, 50A BBSHD Controller Mod

Post by racingame » Feb 13, 2018 5:42 pm

Hello, how do I know if my BBSHD controller has the 3077 MOSFETS? Also, in another article regarding replacing MOSFETS for old BBS02 (https://electricbike-blog.com/bbs02-controller-mods/) it was suggested to replace with these other types:
https://www.digikey.com/products/en?x=1 ... PP034NE7N3 (mid quality)
https://www.digikey.com/products/en?ven ... SD19536KCS (high quality)
Expecially the latter, I think it should be better than the 3077, right? I would like to get the least possible heat from my controller, also possibly building a totally new housing for better dissipation. I don't know if anyone else already thought about that as well.

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Feb 13, 2018 8:07 pm

I don't know how to tell without taking it apart and looking at the markings on the FETs.

I have seen an enhanced housing with extra cooling fins that Luna makes. Not sure if they are sold separately or not.
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Re: How To, 50A BBSHD Controller Mod

Post by tomjasz » Feb 13, 2018 10:15 pm

racingame wrote:
Feb 13, 2018 5:42 pm
Hello, how do I know if my BBSHD controller has the 3077 MOSFETS? Also, in another article regarding replacing MOSFETS for old BBS02 (https://electricbike-blog.com/bbs02-controller-mods/) it was suggested to replace with these other types:
https://www.digikey.com/products/en?x=1 ... PP034NE7N3 (mid quality)
https://www.digikey.com/products/en?ven ... SD19536KCS (high quality)
Expecially the latter, I think it should be better than the 3077, right? I would like to get the least possible heat from my controller, also possibly building a totally new housing for better dissipation. I don't know if anyone else already thought about that as well.
You don't and several resellers were dishonest about when they transitioned. Many BBSHD did not have 3077, and that was not a problem until the motors were pushed beyond 30A. You could always buy a late version controller for around $100 and keep the original for an emergency spare. I always keep a backup. I hate downtime.
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Feb 14, 2018 12:22 am

I know the BBSHD I'm running has the shitty 75NF75 FETs, but it still does amazingly well. I don't run 30A for long periods either, but the motor heating is more of an issue than the controller heating for me. Someone measured one with a FLIR and the temps around the controller are higher than the rest of the motor, so minimizing this is probably a good thing.
"One test is worth a thousand opinions"

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Re: How To, 50A BBSHD Controller Mod

Post by racingame » Feb 14, 2018 12:00 pm

Has anybody tryed to use liquid metal pastes in place of the stock thermal grease on the MOSFETs plate? I think it should lower the temperature.

Image

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Re: How To, 50A BBSHD Controller Mod

Post by espresso » Feb 15, 2018 8:22 am

If I am going to be replacing mosfets with better quality and higher voltage ratings, would this be a suitable candidate for this kind of modification?

https://em3ev.com/shop/bafang-bbs02-48v ... ontroller/

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Feb 15, 2018 9:27 am

espresso wrote:
Feb 15, 2018 8:22 am
If I am going to be replacing mosfets with better quality and higher voltage ratings, would this be a suitable candidate for this kind of modification?

https://em3ev.com/shop/bafang-bbs02-48v ... ontroller/
It will be potted, so difficult to replace the FETs. If it has the 3077 FETs installed, those are not bad.
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Re: How To, 50A BBSHD Controller Mod

Post by racingame » Feb 15, 2018 9:37 am

From what I read on other threads, you cannot go over the standard 25A on the BBS02 since the circuit was not designed with enough room to withstand the extra power like the BBSHD.

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