Connecting Controller To 60 Volt Ping Battery Causes Damage

[cruiserbikeman]

I receive this battery Monday. Charged it up. Connected it to the ampedbike controller and tested the throttle and worked like a charm! Took it out for a ride Tuesday and everything was fine. Today I decided to work on switching over to the Lyen controller. I had changed the power leads and phase wires over to anderson connectors. The ampedbike wires already has andersons on the phase wire. I only had the phase wires connected, nothing else. Connected yellow to yellow, green to blue, blue to green. Then I connected the battery wires from the Ping Battery to the Lyen controller battery wires. There was a huge spark. I disconnected within 2 seconds. The pictures show the results of what happened:


I thought the battery was toast! However, I reconnected it to the ampedbike controller and it still works. I then hooked it up to the charger to see if the BMS would function The BMS still works and the battery still charges. The bike runs at turbo speed. No smoke or anything after taking a ride for 5 miles. It looks like the problem was not the wire but where the lead on the battery connects to the negative wire. It's not broke or anything but seems like excessive current or voltage heated up things melting the tape and plastic shrink wrap. Oh ,by the way, I checked the voltage on the 60 volt Ping Battery with a multimeter. It was at 72 volts off the charger. I did this 6 times. Just to make sure this wasn't a mistake, I checked the voltage on the 48 volt Ping Battery and it was 55 volts. I guess I'll see what happens in the coming weeks.

 

[neptronix]

Beware.
The voltage limit on the ampedbikes controller is 63v as dictated by the capacitor voltage rating and FET rating.

I would open up the ping battery and see what went kaboom.

You may have the polarity reversed on the battery cables of the lyen controller, btw. Did that once. The solder on cell 10 of my lipo pack literally leaped off the board, leaving a charred mess inside one of the packs.

but the controller lived

 

[cruiserbikeman]

Beware.
The voltage limit on the ampedbikes controller is 63v as dictated by the capacitor voltage rating and FET rating.

I would open up the ping battery and see what went kaboom.

You may have the polarity reversed on the battery cables of the lyen controller, btw. Did that once. The solder on cell 10 of my lipo pack literally leaped off the board, leaving a charred mess inside one of the packs.

but the controller lived

The battery wires were connected correctly (red to red) (black to black). Anyway, it seems the battery wire and lead is exposed. I can see blue electrical sparks going through them. It looks like the problem is with the BMS. I'm shutting it down.

 

[dogman dan]

The fat spark you get connecting to the capacitors in a controller is normal. It tends to scorch the plug usually. I suspect something was not right on the bms itself, and cooked off some funky solder or something.

Look up pre charge resistors, to rig up a way to limit the inrush. I've never had a controller get damaged by it, but some say it can happen.

 

[dnmun]

sounds like a bad connection inside the pack. you have to cut it open so we can see what is going on and where the sparks are coming from. disconnect the sense wire plug first.

 

[cruiserbikeman]

The culprit is something on the BMS. Ping is sending me a new one.

 

[dogman dan]

Good for Ping. It did not sound like anything your fault. Pain for you though, to be the lucky one that got the flaky bms.

 

[Diamondback]

Pain for you though, to be the lucky one that got the flaky bms.

I know that feeling ! (though mine didn't make fireworks !)

my 48V ping arrived with a flaky BMS also. after a few weeks of head scratching and trouble shooting, Ping sent me a new BMS also.
in 2000+ KM ive not had another issue with the battery.

Jason.

 

[cruiserbikeman]

I finally have the 60 volt battery back up and running! Soldered the new board thursday. Took it for a short test ride friday evening. Needed to put more air in the 40 psi tires (only had 24 psi air in the tires). Went for an 8 mile ride on saturday and it was good. Really fast! Pedestrians and even car drivers (when i was at at stop lights) were saying they like my bike! Life is good again.