Singlespeed10
100 µW
I just built a Euro-spec Pedelec for my wife with her existing hybrid mountain bike and parts purchased from BMSBattery.com – no issues with the order which was fast, smooth, and accurate. I have a Bafang 500W BPM motor, 36V – 15A Li-Ion battery in a AL case, and S06S 250W sine wave controller. I am deliberately under powering the motor to maximize longevity. This spec with the PAS is perfect for my wife to keep up with her compulsive, roadie husband.
Issue
The components went together easily, worked great, and then quit after less than 100 miles. On one ride we briefly noticed (1 second) and electrical burning smell after topping a short but steep hill - no obvious negative effects were observed. On a second ride we noticed the same brief burning smell immediately in the middle of a short, steep climb after which the unit immediately failed. The LCD1 display intermittently indicated 06_Error which means “Motor or controller has short circuit Abnormality”, according to the user manual.
Troubleshooting
I have tested a number of things and now believe that one of the controller Mosfets failed. Here’s what I did:
1. Dismantled the motor and found no obviously burned wiring.
2. Tested the motor halls and observed the proper switching from 0 to 5V for each as I spun the wheel http://www.ebikes.ca/documents/HallSensorTestingFinal.pdf
3. Tested the controller Mosfet continuity per http://www.ebikes.ca/documents/BlownMosfets.pdf and found the following:
Phase Pos Neg
Green 0Ω 11KΩ
Yellow 21KΩ 11KΩ
Blue 21KΩ 11KΩ
From this I conclude that I have a blown Mosfet on the green phase. In addition, the motor is harder to turn with the controller connected which Grin also states is an indicator of a blown Mosfet. However, there is no obvious burning on the Mosfet or any other controller component.
Questions
1. Have I missed something? Am I correct that this is a Mosfet failure?
2. Was this a fluke, did I do something wrong, or did I deserve this because this is a really crappy controller. I don’t want to spend a fortune on a new controller for what is a rather power modest requirement, but I don’t want to replace it after another 100 miles either.
3. Should I just replace the Mosfets with IRFB4110s? Any advantage to getting branded ones for $5/ea. at Digikey? Or are the eBay Mosfets from China OK at about $1/ea.?
4. Controller replacement choices that I have considered:
• BMS SO6S: If this was a fluke and this is a reasonable choice I’ll buy another from BMS: $24 + $35 shipping = $59.
• BMS S12S: I’d get this if it is more robust for my application (12 Mosfets) AND I can set it with the LCD display to limit the power to ~250W: $34 + $ shipping = $69.
• Cellman 6 fet IRFB4110 Infineon controller http://em3ev.com/store/index.php?route=product/product&path=38&product_id=78 with the ability to program it using XPD open source software http://endless-sphere.com/forums/viewtopic.php?f=2&t=27927#p403201: $76 + $25 shipping = $101.
Any assistance will be appreciated.
Issue
The components went together easily, worked great, and then quit after less than 100 miles. On one ride we briefly noticed (1 second) and electrical burning smell after topping a short but steep hill - no obvious negative effects were observed. On a second ride we noticed the same brief burning smell immediately in the middle of a short, steep climb after which the unit immediately failed. The LCD1 display intermittently indicated 06_Error which means “Motor or controller has short circuit Abnormality”, according to the user manual.
Troubleshooting
I have tested a number of things and now believe that one of the controller Mosfets failed. Here’s what I did:
1. Dismantled the motor and found no obviously burned wiring.
2. Tested the motor halls and observed the proper switching from 0 to 5V for each as I spun the wheel http://www.ebikes.ca/documents/HallSensorTestingFinal.pdf
3. Tested the controller Mosfet continuity per http://www.ebikes.ca/documents/BlownMosfets.pdf and found the following:
Phase Pos Neg
Green 0Ω 11KΩ
Yellow 21KΩ 11KΩ
Blue 21KΩ 11KΩ
From this I conclude that I have a blown Mosfet on the green phase. In addition, the motor is harder to turn with the controller connected which Grin also states is an indicator of a blown Mosfet. However, there is no obvious burning on the Mosfet or any other controller component.
Questions
1. Have I missed something? Am I correct that this is a Mosfet failure?
2. Was this a fluke, did I do something wrong, or did I deserve this because this is a really crappy controller. I don’t want to spend a fortune on a new controller for what is a rather power modest requirement, but I don’t want to replace it after another 100 miles either.
3. Should I just replace the Mosfets with IRFB4110s? Any advantage to getting branded ones for $5/ea. at Digikey? Or are the eBay Mosfets from China OK at about $1/ea.?
4. Controller replacement choices that I have considered:
• BMS SO6S: If this was a fluke and this is a reasonable choice I’ll buy another from BMS: $24 + $35 shipping = $59.
• BMS S12S: I’d get this if it is more robust for my application (12 Mosfets) AND I can set it with the LCD display to limit the power to ~250W: $34 + $ shipping = $69.
• Cellman 6 fet IRFB4110 Infineon controller http://em3ev.com/store/index.php?route=product/product&path=38&product_id=78 with the ability to program it using XPD open source software http://endless-sphere.com/forums/viewtopic.php?f=2&t=27927#p403201: $76 + $25 shipping = $101.
Any assistance will be appreciated.