Bafang BBSxx - fault finding and fixes

Discussions related to motors other than hub motors.
This includes R/C motors, botttom bracket, roller and geared drives.
Post Reply
pompeimtb   100 µW

100 µW
Posts: 7
Joined: Feb 21 2014 7:48am

Re: Bafang BBSxx - fault finding and fixes

Post by pompeimtb » Aug 06 2014 5:16pm

sorry

bbs02 48v 750w
1403110792

I quit clutches and bafang noise perfect.... when i put cltuches and pedal sounds like bearings and growing stronger in each pedal stroke.... i no want buy all piece clutches...


only happens to me when pedaling with the throttle all works perfect

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 06 2014 5:37pm

Has anyone determined the cut off dates for upgrades? For example, all motors after. xx/xx/201X all motors had O ring slot added, or controller was updated. That sure would be helpful info in assisting others in sorting out problems. Yes?

Adding locationmight also help in lining up users with the same native language. Something we also do on Modern Vespa is to take a moment and actually post the appropriate post/thread rather than just responding, "do a search". We consider that bad form. Then again being chatty seems bad form here. :oops:
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.

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 06 2014 6:27pm

My "first" unit (BBS02 48V 750W) is serial number 1311270098 - November 27, 2013, unit #0098 - It has the V2 Connector (Green) and the old O-Ring design without the groove. It is the unit I blew the O-ring on the journal bearing and had to rebuild.

My "Second" Unit, which I purchased from Mikebikerad was an even earlier unit. BBS02 48V 750W serial #1310240062 - October 24, 2013 Unit #0062. This unit is going on a client's bike. I can assume it also has the older O-Ring Design. It also has the V1 Controller connector.
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
Aushiker   100 W

100 W
Posts: 170
Joined: Mar 08 2014 8:47am

Re: Bafang BBSxx - fault finding and fixes

Post by Aushiker » Aug 07 2014 11:51pm

Hi

I have a couple of issues with my Bafang BBS01 36V with the C961.

(1) The battery level shows full irrespective of the level of charge. For example I have ridden 57 kilometres since the first charge yet the display is still showing a full battery. Either I am getting amazing battery life or the display is not correct.

(2) Today I lost throttle. I checked the connection and that seems okay. Everything else is okay, the display is getting power, speed sensor is working etc. It is just the throttle not responding. On my last ride it worked without issue and nothing has been changed since then.

Edit: Serial number is 1402200272

Any suggestions in the meantime?

Thanks
Andrew
Last edited by Aushiker on Aug 08 2014 3:44am, edited 1 time in total.

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 08 2014 12:01am

Aushiker wrote:
The battery level shows full irrespective of the level of charge. For example I have ridden 57 kilometres since the first charge yet the display is still showing a full battery. Either I am getting amazing battery life or the display is not correct.
What is the voltage/cell count of your battery?
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
Aushiker   100 W

100 W
Posts: 170
Joined: Mar 08 2014 8:47am

Re: Bafang BBSxx - fault finding and fixes

Post by Aushiker » Aug 08 2014 1:42am

teslanv wrote:
Aushiker wrote:
The battery level shows full irrespective of the level of charge. For example I have ridden 57 kilometres since the first charge yet the display is still showing a full battery. Either I am getting amazing battery life or the display is not correct.
What is the voltage/cell count of your battery?
Don't know at the moment. It is currently on charge. When I first got it and got a multimeter it was around 41.6 V if I remember correctly. I have no idea how to do a cell count I am afraid.

I should be doing a 20 to 30 km ride tomorrow so will check the battery voltage when I get back. Hopefully that will provide some insight.

I guess I really should install a watts meter :)


Andrew

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 08 2014 7:40am

Link of what you purchased?
Not a good thing if you don't know what your battery voltage is. How do you know. When its fully charged or discharged?
You could be wreaking havoc on those cells...
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
Aushiker   100 W

100 W
Posts: 170
Joined: Mar 08 2014 8:47am

Re: Bafang BBSxx - fault finding and fixes

Post by Aushiker » Aug 08 2014 8:10pm

teslanv wrote:Link of what you purchased?
It was purchased in April, a Bafang BBS01 36v with a Samsung 36V 10S 6P 29E cells 16.5Ah frame pack battery. All from Paul at EM3EV.

Thanks
Andrew

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 08 2014 11:43pm

I would check to see what the Low Voltage Cut-off is set to. If it is much lower than 36V that may be why your display is reading full so long. Also the battery that you have should be a GREAT battery, and the BBS02 is very efficient, so its quite possible everything is fine and you have excellent range. The way to know for sure would be to install a watt-meter in line with the battery lead, and watch the voltage.
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
Aushiker   100 W

100 W
Posts: 170
Joined: Mar 08 2014 8:47am

Re: Bafang BBSxx - fault finding and fixes

Post by Aushiker » Aug 09 2014 12:42am

teslanv wrote:I would check to see what the Low Voltage Cut-off is set to.
I am guessing I need to get a programming cable etc to check for that. Is that right?
The way to know for sure would be to install a watt-meter in line with the battery lead, and watch the voltage.
That has been on the to do list. I think I need to bump it up.

Oh I checked the voltage on a fully charged battery and it came back at 41.7 volts.

Andrew

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 09 2014 1:23am

Here is how to program the controller, and yes, you will need some kind of cable:
http://endless-sphere.com/forums/viewto ... 25#p884525

Fully charged voltage of just under 42V would be right. Fully discharged at rest would be around 36V.
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 09 2014 8:33am

My thumb throttle failed in a week or two. Paul's site suggests ordering an extra with the kit, but I paid no heed. I also find that the meter in the 961 has no reliable level readings.

Tesla, someone suggested adding capacitors as being needed with longer leads when installing a watt meter. Comment?
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.

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 09 2014 9:05am

tomjasz wrote:My thumb throttle failed in a week or two. Paul's site suggests ordering an extra with the kit, but I paid no heed. I also find that the meter in the 961 has no reliable level readings.
If you have your PAS setting programmed appropriately, I think it possible to use this kit without the need for a throttle. I rarely use my throttle.
Tesla, someone suggested adding capacitors as being needed with longer leads when installing a watt meter. Comment?
I'm not familiar with that method.
I connect my watt-metet directly in line with my battery leads, but you can also connect it in a three wire configuration.
http://ecx.images-amazon.com/images/I/7 ... L1500_.jpg
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

tahustvedt   10 kW

10 kW
Posts: 595
Joined: May 26 2014 9:31am
Location: Northern Norway

Re: Bafang BBSxx - fault finding and fixes

Post by tahustvedt » Aug 09 2014 10:09am

Extra capacitors at the controller end will reduce the risk of damaging the capacitors in the controller due to excessive impedance from very long battery leads. When the caps fail, the controller dies quickly. It's common knowledge in the RC airplane world. It might be possible that the Bafang already has very large caps, but judging from the size I doubt it. There might also be other reasons why it's not a problem with bike systems. The current draw is relatively low with Bafang units compared to RC planes, for example. Have there been any failures of units when used with extended battery wires?

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 09 2014 12:45pm

teslanv wrote:
tomjasz wrote:My thumb throttle failed in a week or two. Paul's site suggests ordering an extra with the kit, but I paid no heed. I also find that the meter in the 961 has no reliable level readings.
If you have your PAS setting programmed appropriately, I think it possible to use this kit without the need for a throttle. I rarely use my throttle.
I find that I use PAS more and more and the throttle less. But being a gimp means that there are days when even just moving these old legs is just to much. So, I leave the throttle. I like the LeGrand version far better than the EM3ev supplied.

http://endless-sphere.com/forums/downlo ... ?id=137916 Lectric's
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.

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 09 2014 12:49pm

tahustvedt wrote:Extra capacitors at the controller end will reduce the risk of damaging the capacitors in the controller due to excessive impedance from very long battery leads. When the caps fail, the controller dies quickly. It's common knowledge in the RC airplane world. It might be possible that the Bafang already has very large caps, but judging from the size I doubt it. There might also be other reasons why it's not a problem with bike systems. The current draw is relatively low with Bafang units compared to RC planes, for example. Have there been any failures of units when used with extended battery wires?


Anyone else have a comment before I jump on board?

tahustvedt, what would be an appropriate capacitor and how would it be installed. My Basic DC class is still a month off. I realize I'm asking for a hand hold here, but I'd like to understand before I mess up a controller.

Thanks!

T
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.

tahustvedt   10 kW

10 kW
Posts: 595
Joined: May 26 2014 9:31am
Location: Northern Norway

Re: Bafang BBSxx - fault finding and fixes

Post by tahustvedt » Aug 09 2014 2:28pm

I'm not an expert, but I guess as big as practical,, but bigger will increase the battery connection current inrush (spark). Here's an example of an add on made for RC models: http://www.espritmodel.com/castle-creat ... ppack.aspx

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 10 2014 6:35pm

Not an expert? That's when I hush up. :wink: you sounded as if it were a real problem. We'll see and report back.
Thanks!
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.

Arakasy   1 mW

1 mW
Posts: 10
Joined: Aug 05 2014 8:47pm
Location: Townsville, Qld, Australia.

Re: Bafang BBSxx - fault finding and fixes

Post by Arakasy » Aug 10 2014 8:51pm

Motor works, always has... New battery arrived... So far so good !!!

About to go for a ride and test her out... She is a little baby 250w with a supposedly big battery.. 20AH.

250W is biggest legal size here :(

User avatar
Aushiker   100 W

100 W
Posts: 170
Joined: Mar 08 2014 8:47am

Re: Bafang BBSxx - fault finding and fixes

Post by Aushiker » Aug 11 2014 12:02am

teslanv wrote:
tomjasz wrote:My thumb throttle failed in a week or two. Paul's site suggests ordering an extra with the kit, but I paid no heed. I also find that the meter in the 961 has no reliable level readings.
Paul is coming through with a new throttle. Suggested I might want to add other parts as he is paying the postage :) Pity he does not do a programming cable :)

Andrew

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 11 2014 12:22am

Aushiker wrote:
teslanv wrote:
tomjasz wrote:My thumb throttle failed in a week or two. Paul's site suggests ordering an extra with the kit, but I paid no heed. I also find that the meter in the 961 has no reliable level readings.
Paul is coming through with a new throttle. Suggested I might want to add other parts as he is paying the postage :) Pity he does not do a programming cable :)

Andrew
I'd take the opportunity to get a motor gear and sensor at least. I have a gear stashed. I'm betting on a sensor fail and I didn't get one. $6 from greenbikekit, probably no more from Paul. I'd also ask if he has access to any connectors. Maybe you could score the plug in for the controller? Or a controller extension cable. Worth asking. Seeing I have two motors I'd stash a clutch assembly too. But I tend to be a bit of a hoarder.
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.

tahustvedt   10 kW

10 kW
Posts: 595
Joined: May 26 2014 9:31am
Location: Northern Norway

Re: Bafang BBSxx - fault finding and fixes

Post by tahustvedt » Aug 11 2014 4:48pm

tomjasz wrote:Not an expert? That's when I hush up. :wink: you sounded as if it were a real problem. We'll see and report back.
Thanks!
Hehe. It's a legitimate concern, but there's a limit to my knowledge in any field.

User avatar
tomjasz   10 GW

10 GW
Posts: 4138
Joined: Mar 29 2014 1:45pm
Location: Out riding, MN USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by tomjasz » Aug 11 2014 6:59pm

tahustvedt wrote:
tomjasz wrote:Not an expert? That's when I hush up. :wink: you sounded as if it were a real problem. We'll see and report back.
Thanks!
Hehe. It's a legitimate concern, but there's a limit to my knowledge in any field.
Good humor! thanks!
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.

sputnik2513   1 µW

1 µW
Posts: 3
Joined: Aug 12 2014 12:28pm

Re: Bafang BBSxx - fault finding and fixes

Post by sputnik2513 » Aug 12 2014 12:35pm

Hi everyone, first post.

I just unboxed a new BBS02 500W bought from China (elifebike.com)

and first revolutions... end in the dreaded clicks problem

Here's a video, showing how loud they are
http://youtu.be/JRGq7Qc9lXE

What do you think I should do? Try to send it back to China seller? I don't have a workshop or equipment to dismantle the motor.

Matt

User avatar
teslanv   100 MW

100 MW
Posts: 2675
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Bafang BBSxx - fault finding and fixes

Post by teslanv » Aug 12 2014 12:57pm

sputnik2513 wrote:Hi everyone, first post.

I just unboxed a new BBS02 500W bought from China (elifebike.com)

and first revolutions... end in the dreaded clicks problem

Here's a video, showing how loud they are
http://youtu.be/JRGq7Qc9lXE

What do you think I should do? Try to send it back to China seller? I don't have a workshop or equipment to dismantle the motor.

Matt
Sounds pretty normal to me. It's the tick of the freewheel pawls you hear. If you put a crank on the square bottom bracket and spin it along, the clicking should mostly go away. - And even so, it should get quieter once you break it in a bit.
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

Post Reply