Bafang BBSxx - fault finding and fixes

Discussions related to motors other than hub motors.
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EM3ev Assistance   100 µW

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Re: Bafang BBSxx - fault finding and fixes

Post by EM3ev Assistance » Feb 05 2017 6:08am

heathcliff wrote:Hi guys,

Newbie here.

I purchased a BBS02B 36V 500W motor from em3ev last august. Managed to ride 2000 kms in 3 months last summer. Now that it's stored for the winter I decided to open it to check things and relubricate and while doing so gather information on parts model numbers since I know there are several variations of pinion gear and nylon gear out there. Goal: order spare parts.

Surprisingly, the inside was very clean. Lubrication was sufficient.
The o-ring on the pinion gear at the 12mm end was shredded.
Two o-rings on the crank axle shaft were also destroyed.

Serial number is 1604015447.
Pinion gear model is 3 (a model 2 variation with an o-ring at the 12mm end).
Nylon gear model is X-2.
Chainring gear model is LD-2.
There is also a number engraved on the crank axle shaft: GXY2016-03-28-Z.

Em3ev sent me a replacement 12mm o-ring and a new crank axle assembly, which took almost a month. Not a problem since it's winter. But I would not accept that in the heart of summer, hence my quest for spare parts now.
The replacement chainring gear however is model number LD and it won't fit in with my model 3 pinion gear unless considerable force is applied. The clutch is also different from what I have. The axle itself is different too (only one o-ring instead of 2 adjacent) but it seem to be compatible anyway.

My guess is if you have a chainring gear model LD, the model LD-2 might fit as a replacement. The inverse is not true.

I have photos for those interested.
http://www.ts-export.com/_mb/bbs02_31de ... GP0412.JPG - the replacement chainring model LD em3ev sent me (lubricated before trying to fit it in! - my mistake)
http://www.ts-export.com/_mb/bbs02_31de ... GP0411.JPG - pinion gear model number 3
http://www.ts-export.com/_mb/bbs02_31de ... GP0410.JPG - my original chainring gear model LD-2
http://www.ts-export.com/_mb/bbs02_31de ... GP0409.JPG - notice the orange o-ring on the pinion gear
http://www.ts-export.com/_mb/bbs02_31de ... GP0405.JPG - my original crank shaft, notice 2 grooves for 2 o-rings
http://www.ts-export.com/_mb/bbs02_31de ... GP0404.JPG - idem, one black o-ring (severed), one orange-oring (shredded)
http://www.ts-export.com/_mb/bbs02_31de ... GP0403.JPG - view of the clutch for the LD-2 chainring gear
http://www.ts-export.com/_mb/bbs02_31de ... GP0397.JPG - another view of my LD-2 chainring gear before disassembly
http://www.ts-export.com/_mb/bbs02_31de ... GP0391.JPG - X-2 nylon gear
http://www.ts-export.com/_mb/bbs02_31de ... GP0389.JPG - another view of the model 3 pinion gear
a few clarifications:

1. you requested replacement O-rings only (which incidentally are impossible to source from Bafang). we provided 1 o-ring for the pinion gear and an axle with o-ring fitted. we therefore provided what you requested, plus an axle. I'm sorry that you feel the axle is not a perfect match, but in fact it was not something you requested. We did not charge anything for service parts, they were provided free of charge.
2. all O-rings are orange in colour. there is not 2 O-rings on the end of the shaft, there is 1. There is not a second black 0-ring as you stated.
3. the motor was not faulty when you disassembled it (according to your communications with us). you noticed some damaged O-rings after disassembling the motor.
4. you stated in an email to us: "Will need replacement parts. Not urgent, I have 3 whole months." After we scratched their heads for 2 weeks or more, at how to deal with your request for O-rings, we sent out the parts and included an axle too. we used express DHL shipping to send you the parts. It wasn't made very clear in the emails to us, that you had the latest BBS02B motor.
5. We have not supplied you any gears, so it seems like you are stating that Bafang provided a motor built with the incorrect gears, or internal parts?

If you want to order spare parts, you should state you have the latest version, BBS02B motor (built after April 2016). I would also suggest that if the motor (36V 500W BBS02B) is used moderately as you state, then you are not going to see lots of broken parts and i really do not think you need to go to all this trouble at this stage.

alfantastic   10 kW

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Re: Bafang BBSxx - fault finding and fixes

Post by alfantastic » Feb 05 2017 7:10am

EM3ev Assistance wrote: I would also suggest that if the motor (36V 500W BBS02B) is used moderately as you state, then you are not going to see lots of broken parts and i really do not think you need to go to all this trouble at this stage.
Totally agree, I've been running a BBS02 750w for 3500 miles, with the only problem being the widely documented older MOSFET issue.
Bafang has since addressed this by fitting beefier MOSFETs to their controllers.

Keep these little beauties spinning nice and fast, by using an appropriate gear for the terrain, and they will last a long long time.

heathcliff   100 µW

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Re: Bafang BBSxx - fault finding and fixes

Post by heathcliff » Feb 11 2017 9:07pm

Paul cell_man, I presume? What the hell are you doing with Moon's account? Confusing at least.

Here you are at last. I believe you dislike/hate to talk to chat/phone with end consumers, hence Joseph being hired to alleviate/dispense yourself from than painful chore. Also suspect that you do'nt read the exchanges between Joseph and the clients unless explicitely Joseph forwards the matter to you to because he's not experimented enough to give proper advice every time. So the request comes from Joseph to you, you're are knowing the bare minimum about the dossier.

Nobody is allowed to call me a liar, especially when I can prove with pictures/videos that the other party (you for instance) is at tort. Respectful behaviour is already rewarded; rude comments will be treated in a similar manner. Respect calls for respect. And courtesy sould be tantamount when I send you thousands of dollars in return for goods - all paid in advance!

I hope you'll forget the few days I took to reply to your rude/pretentious 'clarifications'/defamation. I seriously needed to calm down before telling that I'd would not want to. Anger is not of good advice. Ever.

Don't get me wrong. In matter of batteries building/assembling, you're a genius. Concerning the whereabouts of the BBS0xB, your affirmations look like pretentions, unless you've disassembled and reassembled several models. I did.

Now let's review what you've said in post # https://endless-sphere.com/forums/posti ... #pr1262649 which is the heart of the matter, shall we?

a few clarifications:
O-rings - orange

I did not asked replacement o-rings. I stated that 3 o-rings were destroyed after ONLY 2000 kms. Which I consider inaceptable. Not knowing which exact model(s)/size(s) was required, I relied on you to tell me so. Meanwhile I ordered,paid, and received for $50 of misc o-rings from another source (Ebay) which took 2 months. I have received all of them since.

Still pretending that
I would also suggest that if the motor (36V 500W BBS02B) is used moderately as you state, then you are not going to see lots of broken parts and i really do not think you need to go to all this trouble at this stage.
?
Date: Sat, 31 Dec 2016 14:09:14 -0500
From: Marce
To: EM3ev <orders@em3ev.com>
Subject: Re: EM3ev - Order 22348
Lines: 70
User-Agent: Mutt/1.5.23 (2014-03-12)

Hello Joseph,
Hoping my email finds you well,
I've opened my BBS02 for inspection and lubrication.

Fond 2 issues:
1 - One orange O-ring on the mid gear has desintegrated.
It's the one at the top of the device. Not visible in the
picture, I've retrieved bits of it everywhere. The bottom
o-ring is the one that is still in place.
http://www.ts-export.com/_mb/bbs02_31de ... GP0404.JPG
http://www.ts-export.com/_mb/bbs02_31de ... GP0405.JPG
As a result, the shaft is loose in its bearing. Probably
will need replacement.
http://www.ts-export.com/_mb/bbs02_31de ... hanced.jpg

2 - There are 2 o-rings at the drive end of the crank shaft.
One black and one orange. Both were broken/destroyed.
Then I stated a result of o-ring destruction, clearance was now excessive between the 12mm pignion ring and the circular plate. Parts replacement were expected to have a tight fit. In any case I NEVER stated that I would like to get the parts from free. I was willing to pay for them but Joseph
clearly stated once that I will never get spare parts from em3ev unless guaranteed or broken. He said it understand my point of view but nevertheless, should I needed parts from em3ev I'd have to found and order some elsewhere!.


Therefore i ordered some circular/triangular pinion support plate from Doug Sbyner at my expense. It's Canada here and the purchase was $55 and $33 to rerturn the part! So as you could Imagine I'm not very happy about your no spare parts politics! Doug was king enough to issue a complete refund: postage and parts cost! A net 22$ lost!

You've also complained'pretended that you weren't sure that my motor was the new or traditional model. B.S.: you had multiple photos all the time and plenty of time to determine the motor version/model

If you're curious, there are more photos on the website
with numbers ranging from 375 to 407 to document the
process. I'll add more when I relubricate/rebuild it.


I asked Joseph "Is there anything else you'd want me to check?"
He replied "Not at present. I think you have covered everything and the clear photos have made it much easier to see the parts that you require. Measurements, etc?"

You've also complained that I was a liar and there was NO BLACK oring whatsoever at the large gear of the crank shaft. Cheap shot and total absence of competence:

I have 3 photos proving the contrary:
Will need replacement parts. Not urgent, I have 3 whole
months.
If you're curious, there are more photos on the website
with numbers ranging from 375 to 407 to document the
process. I'll add more when I relubricate/rebuild it.

1. you requested replacement O-rings only (which incidentally are impossible to source from Bafang).
How am I supposed to know that? You could at least provide measurements so I could source elsewhere!.
we therefore provided what you requested, plus an axle. I'm sorry that you feel the axle is not a perfect match, but in fact it was not something you requested. We did not charge anything for service parts, they were provided free of charge.
So what! Stop whining for Christ sake! How I am supposed to be aware of that? Who as asked to provided free of chage? Who asked you to use DHL: It's a terrible company. And when you send random part (unrequested) please at least provided parts that do fit and are compatible!

2. all O-rings are orange in colour. there is not 2 O-rings on the end of the shaft, there is 1. There is not a second black 0-ring as you stated.
False: already established!. B.S. again. I have photos clearly showind them. OK black on black background has not the best contrast. If you only took the time to examine them, zoom in , you'd clearly see them and not insulted me being an lowlife liar!

3. the motor was not faulty when you disassembled it (according to your communications with us). you noticed some damaged O-rings after disassembling the motor.
Were we agree finally.

4. you stated in an email to us: "Will need replacement parts. Not urgent, I have 3 whole months." After we scratched their heads for 2 weeks or more, at how to deal with your request for O-rings, we sent out the parts and included an axle too. we used express DHL shipping to send you the parts. It wasn't made very clear in the emails to us, that you had the latest BBS02B motor.
You're problem; not mine. I had 3 full months, well 2 actually since you managed to waste 1 already in 'scratching their heads for 3 orings. And How I possibly know Bafang issues a newer model that precise day of manufacture. You should have do that, so you are the incompent here.
5. so it seems like you are stating that Bafang provided a motor built with the incorrect gears, or internal parts?
B.S. Again. Pure speculation from your part!

How do you caly that large rotary part with multiple (~22) gears at the larger extremity of the Axle? - i HAVE PICTURES OF THAT MAN!
B.S. Again. This a gear, that one you're pretending never sending me!- That is what you sent to me: http://www.ts-export.com/_mb/bbs02_31de ... GP0412.JPG
!

If you want to order spare parts, you should state you have the latest version, BBS02B motor (built after April 2016). I would also suggest that if the motor (36V 500W BBS02B) is used moderately as you state, then you are not going to see lots of broken parts and i really do not think you need to go to all this trouble at this stage.
You mean trhat you cannot/ wouldn't track op the parts serial number that I purchased from you but you can extremery well estimate the warranty date expiration. Not very serious!

AND WHAT ABOUT ALL THOSE WE MOTORS listed in this thread on endless sphere SHIPPED BY BAFANG WITHOUT ANY LUBRICATION; MAKING NOISES AFTER 200 KMS, iT'S MY DUTY TO VERIFY IT ALL.

Joined: Fri Dec 23, 2016 10:47 pm

================
1. you requested replacement O-rings only (which incidentally are impossible to source from Bafang). we provided 1 o-ring for the pinion gear and an axle with o-ring fitted. we therefore provided what you requested, plus an axle. I'm sorry that you feel the axle is not a perfect match, but in fact it was not something you requested. We did not charge anything for service parts, they were provided free of charge.
2. all O-rings are orange in colour. there is not 2 O-rings on the end of the shaft, there is 1. There is not a second black 0-ring as you stated.
3. the motor was not faulty when you disassembled it (according to your communications with us). you noticed some damaged O-rings after disassembling the motor.
4. you stated in an email to us: "Will need replacement parts. Not urgent, I have 3 whole months." After we scratched their heads for 2 weeks or more, at how to deal with your request for O-rings, we sent out the parts and included an axle too. we used express DHL shipping to send you the parts. It wasn't made very clear in the emails to us, that you had the latest BBS02B motor.
5. We have not supplied you any gears, so it seems like you are stating that Bafang provided a motor built with the incorrect gears, or internal parts?

If you want to order spare parts, you should state you have the latest version, BBS02B motor (built after April 2016). I would also suggest that if the motor (36V 500W BBS02B) is used moderately as you state, then you are not going to see lots of broken parts and i really do not think you need to go to all this trouble at this stage.
EM3ev Assistance
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P_.S. All my photos are zoomable1
Last edited by heathcliff on Feb 12 2017 7:00pm, edited 1 time in total.

Lurkin   100 kW

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Re: Bafang BBSxx - fault finding and fixes

Post by Lurkin » Feb 12 2017 4:14am

heathcliff wrote: O-rings - orange

... I stated that 3 o-rings were destroyed after ONLY 2000 kms. ... I have received all of them since.
Cool. Which sizes did you reassemble with? Do you have a link? Given the issues you've had, I'd also be having a look at the o-ring situation at the end of the motor shaft as they are usually toast early on.

To be clear, I've only ever seen orange o-rings on these drives, I've never seen a black one nor can I see one in the photos provided. I'm half blind so its totally possible I've missed something there! :lol: the only 'black o-ring' I can see in your photos is the slot the orange o-ring would be sitting in if it hadn't been sliced up. [EDIT] I've been through all your photos and I cannot see a black o-ring, only a black slot for an orange o-ring to sit in

From what I'm reading you need o-rings, which you say you have already purchased... again, perhaps I'm missing something here... is there other parts that are also damaged?

heathcliff   100 µW

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Re: Bafang BBSxx - fault finding and fixes

Post by heathcliff » Feb 12 2017 7:19pm

Thanks for support and don't making a fool of me. Look at the ptoto http://www.ts-export.com/_mb/bbs02_31de ... hanced.jpg

The oring is still in place at the bottom part of the picture surrounded by the green box. It's already severed at the top of the picture.

Again black on black is very difficult to see even with retinex image enhancment.

Other clue, the groove is visible at the top of the picture where the intact black ring would lied in; on the contrary, the oring is still barely visiblenside the bottom of the groove.

Dimessions were 12mm OD by 1.5mm diameter. Maybe a tiny diameter for a 15 or 17 mm shaft!

Hope this helps.

I've kept the broken black oring on my dedk until the new shaft srrivfed. At that point,k I've discarded it.

Always available to answer more questions and give further details.

Being a scorpio, however better remain extremely poilte!

Lurkin   100 kW

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Re: Bafang BBSxx - fault finding and fixes

Post by Lurkin » Feb 13 2017 4:34pm

Interesting, looks like I've learnt something new today!

I'll be taking mine apart again in the near future, will have a closer look.

Did you have links to where you have purchased replacement o-rings from?

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Re: Bafang BBSxx - fault finding and fixes

Post by heathcliff » Feb 14 2017 10:12am

Yes of course. Sorry I forgot
Did you have links to where you have purchased replacement o-rings from?
http://www.cafr.ebay.ca/itm/26280388134 ... EBIDX%3AIT

This seller uses to sell in quantity of 50. I persuaded him that I wanted quantity of 10 in several values ranging from 7 to 17mm OD. He speaks very good english and answer instantly to emails.
He will combine shipping if you ask him by refunding all shipping costs but one.

tomjasz   1.21 GW

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Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Feb 22 2017 8:25am

I have yet to find ANY source tying serial numbers to mechanical changes in BBSxx series motors. Bafang changes at will and does not report or advise resellers. See electric bike blog for one such story.

These cheap mid drives can be a nightmare thanks to Bafangs policies. See Empoweredcycles for his comments on dealing with Bafang and warranties.

There's a rumored meeting of minds to solve customer service issues but when it filters down to home builders is anyone's guess. Bafang is no help and is rumored to be avoiding warranties for home builders.

I like my bbs01's and BBSHD''s but am getting closer to giving up once problems arise. I can't wait for a company that won't service its resellers.
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: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Feb 22 2017 8:34am

If someone can pin down sizes I've found really good sources of quality orings for very low prices. Shipping can be First Class and the cost would be very reasonable, but sizing is critical.

EDIT just spoke with techs at major supplier in the USA and they tell me they can't answer to what the Chinese do, but ALL the orange o rings they've seen are silicon. Number one property,"Poor Wear Resistance" FWIW.
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: Bafang BBSxx - fault finding and fixes

Post by Animalector » Feb 22 2017 10:08pm

I replaced the FETS on the BBS02 controller without success I thought I would post here.. The first failure was an impact with a rock due to bottoming out... replaced the FETs on the shorted phase, and then the symptom was that it ran on throttle for around 5 seconds, then when I closed the throttle, the motor kept spinning. I pedalled backwards or something to get it to stop, and once it stopped it was dead, wouldn't spin again. this time when I pulled out the FETs I decided to measure them all, and discovered that it was only the high side that was cactus.

So this is the photo of the controller...

Image

Going from memory (it's been a week or so since I looked at it) there is a single FET on the 'high' side ( the one on the left), and parallel FETs on the low side. It's the high side FET that keeps blowing, which is on the left.

I thought perhaps there was a gate resistor missing, and it was a floating gate, from the looks there are no components missing except the pads on the far right of the pic. . Can any guru's suggest why perhaps a high side FET might keep blowing? I should probably measure gate resistances. etc etc. maybe there's an issue with the driver and it's feeding 48V to the gate.. don't know..

Thanks
Andy

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Re: Bafang BBSxx - fault finding and fixes

Post by dustNbone » Mar 02 2017 9:45pm

I'm having a very mysterious problem with my BBS02.

I replaced the controller with one from Luna recently, the old one for some reason developed a dead short across the power leads, as well as shorting the motor phases.

So I put the new one in, all the wiring on the motor side looked fine upon close inspection, and the new controller seemed to work fine at first. But now, just seemingly at random, it will cut out motor power, display reads normal, and it will start to stutter like it's hitting LVC, both under throttle and PAS with throttle disconnected. Turning the display off and back on will sometimes (not always, just randomly) show one battery bar, and slowly creep it's way back up to full. The battery has it's own meter which never shows it dropping below 55V, so it's not a dead battery. It will run for a short (.5 secondish) burst, then start to stutter until I lift off the throttle for a few seconds, and then another burst, more stuttering, etc.

Sometimes it won't respond to throttle or PAS at all, I've ruled out a faulty throttle as it does the same thing with the throttle disconnected and engaging the motor by PAS.

I've disconnected the display and plugged in my programming cable to power it up, same thing, display problem ruled out.

Also sometimes upon power up the motor will run for 1/2 second or so with no input whatsoever, this only seems to happen with the throttle connected but again, things are so random it's hard to tell.

Sometimes it will work fine for my entire journey.

Am I missing something here? Is it just a bunk controller? Nothing is happening consistently enough for me to pin it down. All the wiring I can see looks fine.

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Re: Bafang BBSxx - fault finding and fixes

Post by alfantastic » Mar 03 2017 10:03pm

dustNbone wrote: Am I missing something here? Is it just a bunk controller? Nothing is happening consistently enough for me to pin it down. All the wiring I can see looks fine.
Check the connectors inside the controller housing. If you didn't remove all the sealant first time around, it can cause the connector to back out over time.

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Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Mar 05 2017 5:12pm

dustNbone wrote:I'm having a very mysterious problem with my BBS02.



Am I missing something here? Is it just a bunk controller? Nothing is happening consistently enough for me to pin it down. All the wiring I can see looks fine.
I spoke with two vendors last week about an error 30 message. But your not mentioning any error. They have seen instances where the display created problems.

I like empoweredcycles for their trouble shooting kit. $180 You keep the parts you need and send back for credit those not needed.

https://www.empoweredcycles.com/product ... bs02-bbshd
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.

BeachRider2016   100 W

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Re: Bafang BBSxx - fault finding and fixes

Post by BeachRider2016 » Mar 09 2017 6:06pm

My new (less than 2 weeks old) bbs01 is doing the same thing. At first I thought it was low voltage, but realized its definitely the controller. Thinking of buying a bare motor and swap it.
Has anyone figured out how to fix the issue ?
It couldnt have been loose wiring within the motor since I never opened it up. But it happened when I was riding hard on trails for a good hr straight full throttle.
Maybe it burned a fet or something inside ?
Curious what the bafang gurus gotta say.
Thanks

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Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Mar 10 2017 1:54am

BeachRider2016 wrote:My new (less than 2 weeks old) bbs01 is doing the same thing. At first I thought it was low voltage, but realized its definitely the controller. Thinking of buying a bare motor and swap it.
Has anyone figured out how to fix the issue ?
It couldnt have been loose wiring within the motor since I never opened it up. But it happened when I was riding hard on trails for a good hr straight full throttle.
Maybe it burned a fet or something inside ?
Curious what the bafang gurus gotta say.
Thanks
Same thing as? I don't know if Bafang updated the bbs01 but if they used Anderson connectors in any version lke the BBSHD had for awhile, there could be a lose wire without having to open. If it's bullets like most, I doubt a loose wire.

I'd like to know if they upgraded the 01's. I thought about using a 36v controller on a 48v. Only because I have so many 36v batteries. Might be interesting, but most here would scoff at anything that whimpy. But I think it'd be a toughest, if not the fastest mid drive.

That's pretty hard riding for a BBS01. Manufacture date? Could be loose wire. The 36V are pretty easy to overheat, especially if, like the 48V, not kept at higher rpm. Definitely more sensitive than the other models. I have two nearly 3 years now. Great little commuter motor, but riding hard? Nothing less than a 750W IMO. If you run that hard without good gear changes, you will cook it too. The BBSHD seems to be near bullet proof.
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: Bafang BBSxx - fault finding and fixes

Post by alfantastic » Mar 10 2017 5:59am

BeachRider2016 wrote:My new (less than 2 weeks old) bbs01 is doing the same thing. At first I thought it was low voltage, but realized its definitely the controller. Thinking of buying a bare motor and swap it.
Has anyone figured out how to fix the issue ?
It couldnt have been loose wiring within the motor since I never opened it up. But it happened when I was riding hard on trails for a good hr straight full throttle.
Maybe it burned a fet or something inside ?
Curious what the bafang gurus gotta say.
Thanks
Do some basic tests first, before condemning the controller. Disconnect all HiGo plugs from the system and reconnect, but leave the brake cut-offs disconnected.

Go for a test ride and see if things have improved. Be careful, you won't have the safety feature of the brake cut-offs. If you need to cut power to change gear, then either stop pedaling or release throttle.

BeachRider2016   100 W

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Re: Bafang BBSxx - fault finding and fixes

Post by BeachRider2016 » Mar 10 2017 8:11am

It was doing the lvc blinking thing. But anyway, I just got up this morning and about to take the controller off and the darn thing is working fine now. Which means....overheated? motor shut down to prevent further damage?
Im not sure if this is 100% waterproof at the controller wirings, but I did turn the bike upside down and hose it off two days ago after riding 16miles on the beach with occasional splash from waves.
Anyway,
I got the bullet connector type.

Can this controller be modded with better fets?

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Re: Bafang BBSxx - fault finding and fixes

Post by alfantastic » Mar 10 2017 8:46am

BeachRider2016 wrote:It was doing the lvc blinking thing. But anyway, I just got up this morning and about to take the controller off and the darn thing is working fine now. Which means....overheated? motor shut down to prevent further damage?
Im not sure if this is 100% waterproof at the controller wirings, but I did turn the bike upside down and hose it off two days ago after riding 16miles on the beach with occasional splash from waves.
Anyway,
I got the bullet connector type.

Can this controller be modded with better fets?
Maybe you just forgot to fully charge the battery before going out on that ride. I've done this before. Now my charging routine's a little better.

BeachRider2016   100 W

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Posts: 110
Joined: Jul 13 2016 10:42am
Location: North Carolinas

Re: Bafang BBSxx - fault finding and fixes

Post by BeachRider2016 » Mar 10 2017 9:28am

just got in from a quick 15min ride on the corn field (near by). Still good!

Nah, i swapped in a fresh one, then even hooked up directly to the charger with same results. Pretty sure it overheated with all that hill climbing for a good hr. Thus now im looking to upgrade fets

samsavvas   100 W

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Location: South Australia

Re: Bafang BBSxx - fault finding and fixes

Post by samsavvas » Mar 21 2017 12:49am

Hi Folks,

Haven't been to ES for a long while - not through lack of interest mind you - but just lack of time. However I think I need the community's help so here we are! I've just resurrected my old BBS01 250W/36V. It's been in storage for a year or so since last used, now fitted to an Kemper Filibus cargo bike.
https://www.flickr.com/photos/48163544@ ... 9710115611
The new rear wheel has a brand new Sturmey Archer 3 speed with drum brake. I've just been on a test ride and while the drive, gears, brakes etc all seem to work very well, I've noticed a new noise which I suspect I shouldn't be hearing and which wasn't there when the BBS unit was last used.

I've used a S/A 3 speed before in another bike and I'm aware that they make a very gentle high-frequency ticking noise when coasting due to their multiple freewheel pawls and I can certainly hear this with the new hub. However when I powered up the BBS today - both when I used the throttle and when I used the pedal-actuated drive - there was quite a loud lower frequency 'ticking'. Not a clunking or banging or anything I'd associate with a chipped or broken gear inside the BBS. Just a loud ticking sound that increased and decreased with speed and stopped when just coasting the bike under momentum.

I've eliminated the possibility of chain or any other drive train issues - it clearly seems to be coming from inside the BBS unit (which is otherwise working fine). Doses anyone have any experience with this noise and have any idea what might be causing it. Suggestion and insights much appreciated.

Thanks,
Sam.

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Tom L   1 kW

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Location: Tasmania, Australia

Re: Bafang BBSxx - fault finding and fixes

Post by Tom L » Mar 21 2017 5:16am

Have you checked the metal reduction gears are still well lubed up with grease?

You don't have to take the motor off the bike to remove the cover plate.

Mobilgrease 28 is the go. Don't get it on the nylon gear though.

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sannder   10 mW

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Location: Switzerland

Re: Bafang BBSxx - fault finding and fixes

Post by sannder » Mar 25 2017 6:35am

I have a problem with my BBS01B - although, I think it's probably software related.
It's happening only in PAS mode and it's more noticeable when I pull from a stop.

The motor is juddering like a petrol engine in the wrong gear, after 2-3 spins the power is back to normal.
This does not happen when I use the throttle, the power is smooth right from the start.

I have a usb programming cable - any suggestions what parameter I should change ?
It could be that the controller does not detect the movement properly and cuts the power between the sensor signals ?

Animalector   10 kW

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Location: Mareeba - Queensland

Re: Bafang BBSxx - fault finding and fixes

Post by Animalector » Mar 25 2017 4:11pm

Check your start current settings

tomjasz   1.21 GW

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Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Mar 25 2017 5:23pm

sannder wrote:I have a problem with my BBS01B - although, I think it's probably software related.
It's happening only in PAS mode and it's more noticeable when I pull from a stop.

The motor is juddering like a petrol engine in the wrong gear, after 2-3 spins the power is back to normal.
This does not happen when I use the throttle, the power is smooth right from the start.

I have a usb programming cable - any suggestions what parameter I should change ?
It could be that the controller does not detect the movement properly and cuts the power between the sensor signals ?

Are you shifting down and taking off in the appropriate gear as you would without a motor? If so consider the programing guide that Karl's did and is available on other web pages. I've been running the em3ev version for going into my 4th season with our an issue. electric fat bike blog
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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