Befang BBS02 switching off after 10 seconds, Errors 21 and 30, Motor controller status changed to 0x100.

[episani]

Hi,

I'm sorry if this has been asked before.

The problem started a few months ago after hitting a bump, the motor would switch off. To fix the problem I had to switch the battery off, then back on and the bike kept going.

Now I has stopped working completely. When I switch the bike on it goes for a few seconds and then it switches off.

I checked the display for errors, and it has two errors: error 21 and error 30.

According to the documentation, error 21 is related to the speed sensor and error 30 seems to be a communication error between the display and the controller, which is usually related to bad connections between the display and the controller.

I checked all the cables and connections and they seem ok. The speed sensor seems ok too and it shows the speed on the display.

To rule out the display, I connected the programming cable. The error persisted. I switch the battery on, and the throttle switches the motor on, for 10 seconds.

Trying to get more information I installed the open source firmware for the controller, as explained here: BBS-FW: Open Source Firmware for BBSHD/BBS02 Controller

The error persisted, the motor stops working after 10 seconds or so.

With the open source config tool, I can see this error: Motor controller status changed to 0x100.

Looking into the source code downloaded from GitHub - danielnilsson9/bbs-fw: Open source firmware for multiple electric bike motor controllers. I don't have any clues on what's going on.

I'm about to get a new controller as I'm guessing the controller is faulty, but I don't want to spend money in something that might not be the cause of the problem.

Has anyone experienced a similar problem?

Thanking you in advance for your help.

 

[amberwolf]

Since the speed shows on the display, then trhe display is porbably correctly receiving data from the controller.

Can the display correclty change assist levels / modes on the controller? If not, then the comm error is probably the controller not receiving data from the display.

That is usually a connection fault between the two, anywhere between the PCB of one and the PCB of the other. when it isn't that, it's usually a failed tranceiver on the line that's not working, at either end of the line. When it isn't that, it';s probably the actual MCU ouptut at the display or the MCU input at the controller.

The speed sensor error usually means the magnet on the sensor is too close ro too far, but that would give you wrong or no speed reading. So it's probably a crappy error tree in the software that's actually telling you something else that there's no error code for, and the default for that end sup bieng the error you see.

In that event, it might be *related* to the errro seen, so it might be a speed senosr, but not the wheel speed sensor--it might be a pedal speecd (cadence) sensor, or it might even be a throttle sensor error or motor hall sensor error or even a brake sensor error.

 

[episani]

Since the speed shows on the display, then trhe display is porbably correctly receiving data from the controller.

Can the display correclty change assist levels / modes on the controller? If not, then the comm error is probably the controller not receiving data from the display.

That is usually a connection fault between the two, anywhere between the PCB of one and the PCB of the other. when it isn't that, it's usually a failed tranceiver on the line that's not working, at either end of the line. When it isn't that, it';s probably the actual MCU ouptut at the display or the MCU input at the controller.

The speed sensor error usually means the magnet on the sensor is too close ro too far, but that would give you wrong or no speed reading. So it's probably a crappy error tree in the software that's actually telling you something else that there's no error code for, and the default for that end sup bieng the error you see.

In that event, it might be *related* to the errro seen, so it might be a speed senosr, but not the wheel speed sensor--it might be a pedal speecd (cadence) sensor, or it might even be a throttle sensor error or motor hall sensor error or even a brake sensor error.

Thank you for your reply.

I don't think the display is the problem as it receives the speed data and in the 10 seconds the motor works I can set the assist levels too. Also, when I connect the programming device, using the display connector, the motor has full power without control, again for 10 seconds.

I might think it is something loose inside the motor itself as it started happening every time I hit a hard bump.

Once this error happens the motor never works again until I reset the controller by switching the battery off.

Is like it takes 10 seconds for the controller to find an error that shutdown the motor. The display keeps working no problems.

Cheers

 

[aae34]

With the open source config tool, I can see this error: Motor controller status changed to 0x100.

Unsure, but looking at here: NEC Motor Control Protocol

0x0100 might be the controller thinking you're "braking".

 

[amberwolf]

If the controller can't receive data from the display, either because the display is broken, controller is broken, or wires are broken, or any other reason, then it probably times out and shuts down.

So...the things I listed before are the things to check for that particular problem.

If it isn't that problem, which is extremely common in one variation or another with all sorts of controllers that use displays, then you'll have to figure out what the error is really pointing to.

 

[episani]

If the controller can't receive data from the display, either because the display is broken, controller is broken, or wires are broken, or any other reason, then it probably times out and shuts down.

So...the things I listed before are the things to check for that particular problem.

If it isn't that problem, which is extremely common in one variation or another with all sorts of controllers that use displays, then you'll have to figure out what the error is really pointing to.

Unsure, but looking at here: NEC Motor Control Protocol

0x0100 might be the controller thinking you're "braking".

Thank you, maybe that's the reason. Sometimes we look at the most complicated reasons without checking the most obvious ones.

Because it said error in the log, I never thought it could be breaks. But you're right, In that protocol the 0x0100 status is Braking!

 

[aae34]

Thank you, maybe that's the reason. Sometimes we look at the most complicated reasons without checking the most obvious ones.

Because it said error in the log, I never thought it could be breaks. But you're right, In that protocol the 0x0100 status is Braking!

Yep. The brake signal is also shared directly to the mcu actually controlling the motor(, and the mcu which bbs-fw is flashed on isn't it).
So some issue in the wiring/brake sensors is what most likely the cause for this.

 

[episani]

If the controller can't receive data from the display, either because the display is broken, controller is broken, or wires are broken, or any other reason, then it probably times out and shuts down.

So...the things I listed before are the things to check for that particular problem.

If it isn't that problem, which is extremely common in one variation or another with all sorts of controllers that use displays, then you'll have to figure out what the error is really pointing to.

Hi, you were both right! I disconnected the breaks, connected the programmer cable (which leaves the motor connected) and also connected the throttle. The motor works with the throttle all the time.

So I'm guessing the display is faulty as amberwolf suggested and maybe one of the breaks magnet switches (or both) are faulty as aae34 suggested.

I'll get "el cheapo" display like this: https://www.aliexpress.com/item/1005007587900035.html and new break sensors for hydraulic brakes.

My bike is usually exposed to the elements and the magnets of the brake sensors are looking very rusted, so maybe that's causing the brake sensors to fail.

Thank you both for your help!

 

[amberwolf]

Hi, you were both right! I disconnected the breaks, connected the programmer cable (which leaves the motor connected) and also connected the throttle. The motor works with the throttle all the time.

Does it work without the programmer cable?

Does the programmer correctly send data to the controller, and the controller accept the changes and stay changed?

If not, the controller's data RX line is probably damaged, either in wiring, PCB, solder, or parts.

So I'm guessing the display is faulty as amberwolf suggested

I suggested the controller wasn't getting data back from the display, which can be the controller damaged in it's data RX line, or the display in it's TX line.

and maybe one of the breaks magnet switches (or both) are faulty as aae34 suggested.

Easy to test. Use a multimeter and check to see if the voltages change when you engage them, and to what voltage from what voltage.

If they are just switches and not hall or other sensors that require power, you can test them while disconnected, and see if you get continuity when enaged, and no continuity when disengaged.

I'll get "el cheapo" display like this: https://www.aliexpress.com/item/1005007587900035.html and new break sensors for hydraulic brakes.

If you replace the display, make sure it is one that is compatible with your system. Displays and controllers are not generally intercompatible, and just because a display *looks* like the one you have doesn't mean it has the correct firmware, connector, or wiring.

If it has the wrong wiring (with the right connector) you can blow up both your display and your controller, and possibly even throttle, etc., by sending batterry voltage into low voltage signal lines.

Also make sure the sensors you get for breaks are of the correct type for your system--same wiring, same kind of sensor, and same response (most commonly off / open when not pulled, on / shorted when pulled, but some are made differently for systems that require that, so test what yours need first).

 

[DexElex]

It sounds like your controller might need to be replugged can you pull the controller and reseat all the connectors

Cant recommend this screen enough will work across a range of controllers and is very resilient to knocks has all the protocols and works well with OpenSource FW as it works with a good voltage range
| Electric Bicycle T8 LCD Display Colorful Screen 24V 36V 48V 52V 60V 72V Waterproof Electric Bike LCD Display Panel

https://a.aliexpress.com/_EQ4v2ys

 

[episani]

Does it work without the programmer cable?

Does the programmer correctly send data to the controller, and the controller accept the changes and stay changed?

If not, the controller's data RX line is probably damaged, either in wiring, PCB, solder, or parts.



I suggested the controller wasn't getting data back from the display, which can be the controller damaged in it's data RX line, or the display in it's TX line.





Easy to test. Use a multimeter and check to see if the voltages change when you engage them, and to what voltage from what voltage.

If they are just switches and not hall or other sensors that require power, you can test them while disconnected, and see if you get continuity when enaged, and no continuity when disengaged.



If you replace the display, make sure it is one that is compatible with your system. Displays and controllers are not generally intercompatible, and just because a display *looks* like the one you have doesn't mean it has the correct firmware, connector, or wiring.

If it has the wrong wiring (with the right connector) you can blow up both your display and your controller, and possibly even throttle, etc., by sending batterry voltage into low voltage signal lines.

Also make sure the sensors you get for breaks are of the correct type for your system--same wiring, same kind of sensor, and same response (most commonly off / open when not pulled, on / shorted when pulled, but some are made differently for systems that require that, so test what yours need first).

Thank you for your kind replies. I'll post back when I get my new parts

 

[episani]

It sounds like your controller might need to be replugged can you pull the controller and reseat all the connectors

Cant recommend this screen enough will work across a range of controllers and is very resilient to knocks has all the protocols and works well with OpenSource FW as it works with a good voltage range
| Electric Bicycle T8 LCD Display Colorful Screen 24V 36V 48V 52V 60V 72V Waterproof Electric Bike LCD Display Panel

https://a.aliexpress.com/_EQ4v2ys

Thank you for suggesting this display, it looks beautiful and it seems to be compatible with a range of protocols and controllers.