How To, 50A BBSHD Controller Mod

General Discussion about electric bicycles.
Couchy   100 µW

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Re: How To, 50A BBSHD Controller Mod

Post by Couchy » Dec 07 2018 5:37am

Has anyone had any success with higher voltage? I did the shunt mod with my BBSHD Controller but have just received another one I ordered. Thinking of doing the 100v mods with caps and fets and building a cheap lipo pack for it. Did anyone end up replacing the psu chip?

E-mil   10 mW

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Re: How To, 50A BBSHD Controller Mod

Post by E-mil » Dec 11 2018 8:58pm

Couchy, I have some thoughts on 100 V, as it might not be that difficult to do.
First, I'd measure the voltage on the psu chip's Vcc voltage. If we're in luck, it's the same as displayed on the display (Vdrop mod). If not, it sees the pack voltage. I figure it's not the end of the world then, since I would try to do another Vdrop mod, this time for the psu chip.
The chip/logic power draw might be so small that a simple zener diode could suffice. - Fechter, what you think?
Next time I pull the controller apart I'll trace the traces/connections on the controller board anyway to get an idea. 👍

Enric   1 mW

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Re: How To, 50A BBSHD Controller Mod

Post by Enric » Dec 17 2018 7:00am

Hi guys,
I had an accident removing the pot of my second BBSHD and loose a component.

Some one can say me the value of that resistor ?
resistencia_bbshd.jpg
resistencia_bbshd.jpg (483.08 KiB) Viewed 1088 times
It looks it's write 512 that means 5100 Ohm.

Can some one confirm this?

Or it's 572 taht means 5700Ohm?

Regards

Enric

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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Dec 17 2018 10:10am

I checked one I have here. It's 5200 ohms.
"One test is worth a thousand opinions"

Enric   1 mW

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Re: How To, 50A BBSHD Controller Mod

Post by Enric » Dec 17 2018 1:47pm

Thanks for the info.

Andrewol   10 W

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Re: How To, 50A BBSHD Controller Mod

Post by Andrewol » Dec 28 2018 4:57am

Couchy wrote:
Dec 07 2018 5:37am
Thinking of doing the 100v mods with caps and fets
What about other smd passive and active components on the pcb? Are they 100V rated?

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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Dec 28 2018 12:13pm

Andrewol wrote:
Dec 28 2018 4:57am
What about other smd passive and active components on the pcb? Are they 100V rated?
No, they are 80v rated but the MCU shuts down at around 63v, so the rest of the stuff has to be fed with a lower voltage. Only the main caps and FETs need the full voltage.
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Andrewol   10 W

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Re: How To, 50A BBSHD Controller Mod

Post by Andrewol » Dec 28 2018 7:19pm

We can't be sure for smd caps. 63V is a standard rating voltage for them, while 80V isn't. Smd transistors, diodes should be rated 90V or higher. All of the stuff on the pcb should receive full voltage potential unless there are components in the circuit set to maintain it at lower range. Btw, you could measure the components voltage manually on pcb to be 100% sure. I still hasn't bought my BBSHD yet.

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Matador   10 kW

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Re: How To, 50A BBSHD Controller Mod

Post by Matador » Jan 06 2019 7:28pm

Saw this on youtube !! Nice!



Shunt mod at 30:00.

Matador

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tomjasz   10 GW

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Re: How To, 50A BBSHD Controller Mod

Post by tomjasz » Jan 07 2019 10:59pm

Yeah, I’ve tried to get him to reveal more given therepairs he’s done. No luck yet...
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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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Jan 08 2019 9:22am

Andrewol wrote:
Dec 28 2018 7:19pm
We can't be sure for smd caps. 63V is a standard rating voltage for them, while 80V isn't. Smd transistors, diodes should be rated 90V or higher. All of the stuff on the pcb should receive full voltage potential unless there are components in the circuit set to maintain it at lower range. Btw, you could measure the components voltage manually on pcb to be 100% sure. I still hasn't bought my BBSHD yet.
The two main caps are rated for 63v and go directly across the battery input. Pretty much everything else goes through the display and then to a voltage regulator on the main board. As long as the feed going to the display stays under 63v, everything downstream will be fine.

There are some small SMD MLCC caps across the power bus and ones between the phase wires and ground. They have no markings. To be sure, you would want to upgrade those too.
"One test is worth a thousand opinions"

Andrewol   10 W

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Re: How To, 50A BBSHD Controller Mod

Post by Andrewol » Jan 08 2019 10:22am

Perhaps someone would be willing to make a schematic (some kind of reverse engineering) for controller pcb, than we will know for sure if everything else goes through the display and then to a voltage regulator on the main board. I would do it if I had the board.
Fechter, have you tried your transistor Vdrop mod?
E-mil, do you have any updates in checking the psu chip's Vcc voltage is it the same as display or pack voltage?

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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » Jan 08 2019 3:31pm

Andrewol wrote:
Jan 08 2019 10:22am
Fechter, have you tried your transistor Vdrop mod?
No, but somebody else did it to run 72v. They used a simple TVS diode.

Reverse engineering the entire board would be very time consuming. I have reverse engineered the important parts of it using a dead one (cadaver study).
"One test is worth a thousand opinions"

Cbisbaf   1 mW

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Re: How To, 50A BBSHD Controller Mod

Post by Cbisbaf » May 06 2019 9:44am

Anyone know how to sort this out what resistor i need to change. passed from pillar to post someone saying firmware and someone else saying new controller. it stops showing error 07 at about 57.5v but it winds me up having to drain my battery to that every time. tried asking luna and there was a wall placed right in front of that because i bought from china. also i have the dpc18 if that changes anything. i have tried settings via a usb ftdi no joy. also i have a microscope and rework station so the small stuff is fine for me.
cheers in advanced
Attachments
IMG_20190504_204144.jpg

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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » May 06 2019 10:58am

Cbisbaf wrote:
May 06 2019 9:44am
it stops showing error 07 at about 57.5v but it winds me up having to drain my battery to that every time.
Dang, you're pretty close. Just needs about another volt or so. I would just use some regular diodes in series with the display power line. Something like a 1N4004. Two in series would drop it by about 1.4v so would allow you to fully charge the pack and still run. You could try it with one diode first and see if that is enough.

Diode would go in series with the brown wire going from the controller to the display. This can be installed anywhere between the motor and display. I would personally install it in the controller. You can dig the potting out around the main cap and get to the brown wire there.
BBSHD unpotted Display Power Line.jpg
BBSHD unpotted Display Power Line.jpg (113.08 KiB) Viewed 564 times
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tomjasz   10 GW

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Re: How To, 50A BBSHD Controller Mod

Post by tomjasz » May 06 2019 12:34pm

Cbisbaf wrote:
May 06 2019 9:44am
Anyone know how to sort this out what resistor i need to change. passed from pillar to post someone saying firmware and someone else saying new controller. it stops showing error 07 at about 57.5v but it winds me up having to drain my battery to that every time. tried asking luna and there was a wall placed right in front of that because i bought from china. also i have the dpc18 if that changes anything. i have tried settings via a usb ftdi no joy. also i have a microscope and rework station so the small stuff is fine for me.
cheers in advanced
It's likely a firmware issue if a new motor.
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 Cbisbaf » May 06 2019 1:22pm

its about a week old do i need one of them besst connectors for that? if that's the case then its getting 2 diodes haha thank you for helpful responses its took me 2 days to find some genuine people :bigthumb: :bigthumb: :bigthumb:

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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » May 06 2019 2:03pm

I suppose there's a chance that it's just programmed for a 48v battery and you could fix it with a programming cable and the software. You might try to find someone in your area that has one you can borrow. I don't know how to tell the pack voltage programming without the cable.

If you put diodes in the line to drop the voltage, keep in mind your display voltage will read lower than actual by a fixed amount.
"One test is worth a thousand opinions"

Cbisbaf   1 mW

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Re: How To, 50A BBSHD Controller Mod

Post by Cbisbaf » May 06 2019 2:42pm

fechter wrote:
May 06 2019 2:03pm
I suppose there's a chance that it's just programmed for a 48v battery and you could fix it with a programming cable and the software. You might try to find someone in your area that has one you can borrow. I don't know how to tell the pack voltage programming without the cable.

If you put diodes in the line to drop the voltage, keep in mind your display voltage will read lower than actual by a fixed amount.
i would like to try the software route first do you think its possible with a ftdi or does it need to be the bafang besst tool

BotoXbz   10 W

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Re: How To, 50A BBSHD Controller Mod

Post by BotoXbz » May 06 2019 4:42pm

Here's the latest firmware for the BBSHD btw. that fixes the overvolt error: https://i.botox.bz/CRR10E5228E1050221_190418.bin

Edit: Okay, I just tried with the Bafang BESST Software and a CP2102 UART Dongle and wasn't able to get any response from the motor, the BafangConfigTool works fine but BESST can't connect to the motor at all.

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fechter   100 GW

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Re: How To, 50A BBSHD Controller Mod

Post by fechter » May 06 2019 11:17pm

I think the motor firmware gets flashed though a connector on the board, not the cable. I've never done it though.
A ftdi board is the same as the Bafang tool as far as I know. You just need to wire a connector for it.
"One test is worth a thousand opinions"

Cbisbaf   1 mW

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Re: How To, 50A BBSHD Controller Mod

Post by Cbisbaf » May 06 2019 11:57pm

BotoXbz wrote:
May 06 2019 4:42pm
Here's the latest firmware for the BBSHD btw. that fixes the overvolt error: https://i.botox.bz/CRR10E5228E1050221_190418.bin

Edit: Okay, I just tried with the Bafang BESST Software and a CP2102 UART Dongle and wasn't able to get any response from the motor, the BafangConfigTool works fine but BESST can't connect to the motor at all.
Will give it a go tonight when I get home from work. What chip is on the board might reach out to some of my quadcopter palls and see if they can conjure up some open source software. I have already had a cable plugged in and used the Luna/ penoff software is that what we are calling the besst software. Also from experience firmware is upgraded by forcing the chip into boot mode then flashing. Can't be done through normal connection. In that case an ftdi will only work then.

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Re: How To, 50A BBSHD Controller Mod

Post by amberwolf » May 08 2019 3:06pm


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