Fellas, I am stumped. Need some help trouble shooting. Getting increasingly dis-interested in pedaling this bike around to the point of even thinking of selling.....
Completed the bike buld in 11/11 with the following set up:
24s A123/20ah pack/ 18X4115 Lyen controller / pre-disc 5303 with stock phase and hall wires.
After getting the bike set up, I had the controller set to about 40 amps max, with the LVC set accordingly for my lifepo4 pack.
From late november in 2011 until late january in 2012, I ran the bike with no problems back and forth to work, running the bike no longer than about 25 minutes at a time. During the this commute, I would do a little over 8 miles each way, and I am getting about 1.5 miles per amp hour.
In late january, I rode the bike on the first "long" ride - continuous fun ride. At around the 14-15 mile mark, I lost all power to the hub motor.
No power to the CA through the controller.
However, when turning the power on at the controller, current was reading properly at the phase wires.
After getting the bike home, I pulled the motor, checked the hall sensors for proper function. They were fine.
I then checked the wiring (hall/phase) for insulation issues. The wiring was fine.
Re assembled the motor, wired up
After some controller diagnosis, I determined tha a few fets were fried in the 18X4115.
Repaired the controller, reconnected everything, and immediately bike fired up and worked no load.
Took the bike for its first shake down run and it only made it about 1.25 miles on a WOT pull before shutting down.
Sent it back to LYEN for a 4110 controller.
Received the new controller, wired it up, everything has been working properly,except that I have yet to make it all the way home with out the battery pack cutting out.
The first time on the way home, I made it into my drive way and the pack cut out. I figured I made a mistake programming my LVC and made an adjustment.
The second to last attempt at commuting, on the way home, at about the 14.5 mile mark, I lose all power. the only way I regain power is by plugging my chargerback in to the battery charge port, thus powering up the BMS. had to pedal about 1.25 miles back to the house.
This happened two days ago on my "evening commute" vid. When I got home, I pulled the side panel, charged the pack to full voltage, pulled the balance leads off the bms for the subpacks, and measured full charge voltage in my 24s pack. All cells at ful charge were at 3.66 volts
Tonight, on the way home @ 14 ish miles, I again lost power and could not get the pack to power up the controller again until I got home, put the pack n the charger for a second, and my CA lit up reading 79 volts.
I again pulled the side panel off my bike, checked the balance leads on each cell. ALL cells were reading 3.28 volts.
I am losing all power at 14 miles, and about 8.6 ah used. This pack should be yeilding a full, usable 17-18 AH, and neither the BMS or the Controller should be cutting power due to LVC. Given that kind of capacity and my 1.5 miles/ah riding style, I should see close to 30 miles range before the LVC even gets close to acting on the controller or BMS. The BMS is set for 2.0 volts, the controller set for 2.2 volts per cell.
What else can it be? The only other thing I can thin is that either I missed or screwed up some insulation on the re-wire of the hub motor and it is causing a short that is somehow tripping the BMS, or the BMS is faulty.
Controller is good, hall sensors are good, all cell voltages are balanced in the pack. It seems like the same issue is still prevalent that existed from day one.
It is only after I plug the charger back into the pack that the controller powers up again. If I do not do this, then unplug/plug the power leads from the battery to the controller, there is no arcing or spark as you would normally see from an 80 volt pack. This indicates to me that the BMS is "off" not allowing current to pass through the power leads.
any help is appreciated. I need some fresh perspective....