BBS02B 750W overheated - problem

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Kova_PL   1 µW

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Joined: Jul 11 2018 8:25am

BBS02B 750W overheated - problem

Post by Kova_PL » Jul 11 2018 8:29am

Hello,
I am looking for expert advice what part of engine may have been damaged. The problem occurred after 15 minutes of driving with full power in the muddy terrain. The driver showed the check engine icon and the engine stopped and it was very hot. After cooling, the engine works very loud (like a tram) and after a while it turns off. I opened the engine but I can not determine what is damaged.
I hope that someone can find out what is damaged.
1. engine rotor and its gear looks fine, bearing works fine for me
2. pinion gear looks fine and its bearing works fine - but its end looks like overheated.
3. nylon gear looks fine and its bearing works fine
4. biggest gear looks fine
5. engine core smells like overheated

I put photos and video on the dropbox:
https://www.dropbox.com/sh/z196of815rkj ... LEJfa?dl=0

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Ivanovitch_k   10 W

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Location: Paris, France

Re: BBS02B 750W overheated - problem

Post by Ivanovitch_k » Jul 12 2018 5:17pm

windings are discolored. They might be toast :(
BBS'ed Radon ZR Team 8:
BBS02B 750W - DPC750C - 48V 17.5Ah GA shark - 11 spd 11-40 Shimano XT, 42T N-W Precialps CW, KMC X11e chain, Gearsensor, XT RD, XTR Shifter, F Saint Brake, R XT Brake, RT99 200/160 Discs, magnetic shutoff, DT Swiss X1900 QR9 wheels, Manitou M30 air fork, 2.4" slick balloon schwalbe Super Moto X tires @2 bars, Suntour NCX suspension seatpost, ergon SFC3 saddle, ergon GP3 grips, Supernova M99 Pro + E12 Taillight

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ginekolog   100 mW

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Location: Slovenia, Europe

Re: BBS02B 750W overheated - problem

Post by ginekolog » Jul 14 2018 2:43pm

I had same symtopms. After cooling down motor worked but can only run on 200W. Anything more will overheat it. My windings are black burned. I have BBSHD now, it is much better motor for running at 800-1200w .
Giant Trance X2 + BBSHD + 52V + 17,5 Ah = :bolt: :bigthumb: :D

Kova_PL   1 µW

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Re: BBS02B 750W overheated - problem

Post by Kova_PL » Aug 06 2018 1:41am

Anyone can advice, where can I buy engine core replacement (stator or stator+rotor) in Europe or in China? Unfortunately Bafang doesn't replies.

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Ivanovitch_k   10 W

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Joined: Jul 15 2017 4:54pm
Location: Paris, France

Re: BBS02B 750W overheated - problem

Post by Ivanovitch_k » Aug 06 2018 1:25pm

Kova_PL wrote:
Aug 06 2018 1:41am
Anyone can advice, where can I buy engine core replacement (stator or stator+rotor) in Europe or in China? Unfortunately Bafang doesn't replies.
try declic-eco in France, as a custom order. The owner is specialized in BBS repairs.
BBS'ed Radon ZR Team 8:
BBS02B 750W - DPC750C - 48V 17.5Ah GA shark - 11 spd 11-40 Shimano XT, 42T N-W Precialps CW, KMC X11e chain, Gearsensor, XT RD, XTR Shifter, F Saint Brake, R XT Brake, RT99 200/160 Discs, magnetic shutoff, DT Swiss X1900 QR9 wheels, Manitou M30 air fork, 2.4" slick balloon schwalbe Super Moto X tires @2 bars, Suntour NCX suspension seatpost, ergon SFC3 saddle, ergon GP3 grips, Supernova M99 Pro + E12 Taillight

brone   10 mW

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Re: BBS02B 750W overheated - problem

Post by brone » Aug 10 2018 4:10am

Kova_PL wrote:
Aug 06 2018 1:41am
Anyone can advice, where can I buy engine core replacement (stator or stator+rotor) in Europe or in China? Unfortunately Bafang doesn't replies.
Green ebikes kit - google search it

Kova_PL   1 µW

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Re: BBS02B 750W overheated - problem

Post by Kova_PL » Aug 10 2018 7:34am

Even greenEbikeKit don't have it. They will try to rise quanity to get it from bafang. It looks like the USA is the only source.
I decide to rewind the engine.

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Alan B   100 GW

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Re: BBS02B 750W overheated - problem

Post by Alan B » Aug 10 2018 8:44am

The Hall sensors are easily damaged by overheating. They control the timing of the current to the motor, so if damaged the motor won't run smoothly and could get hot fast. The halls usually fail before the motor insulation.

The windings changing color is the insulation being overheated from too much current. If it gets too overheated it may fail and short. Rewinding might be required. This is a sign of running in the wrong gear. Downshifting to run the motor faster will reduce heating. Torque comes from current, but heat comes from current squared so run in the gear that allows the motor to spin near max RPM for lowest heating.

Bafang parts have been a problem. When buying a kit, choose a dealer that carries spare parts, but most do not and the factory does not seem to either.

Kova_PL   1 µW

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Re: BBS02B 750W overheated - problem

Post by Kova_PL » Aug 11 2018 3:56am

Thank for advice with Hall sensor. I have run motor without nylon gear. Works the same - heats 80°C in 1 minute, its laud, works not fluent on one throtle setings (A changes) and it stops from time to time.
Windings are black so it have to be changed. If it don't help I will have to replace hall sensors fallowing your advice.

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