DIY Fix for BBS02/BBSHD Pedal/Throttle Issue

[hrasco]

I am currently looking for a source of Darlingtons. The joys of supply chain.
Cheers and thanks for this thread.

Pretty much any NPN Darlington will work. Some may have different pinouts or package sizes.
There is a way to update the firmware on the controller to solve this problem
See this topic:
https://endless-sphere.com/forums/viewtopic.php?f=28&t=100064

Thanks for your reply. I was able to find a "non lead free" version on Mouser. The more common versions were out of stock and their restock window was months out. I installed the fix and it seems to be working fine.

Thanks also for the link. There was some really good information therein. I was still not able to determine whether the firmware would work on a BBS02 or if there was a different firmware that would. The thrust of the thread was a voltage issue on the BBSHD and I am seeking a fix for the throttle issue on the BBS02. I discovered my older 02 bike has had the same problem and I don't want to tear it apart if I don't have to.

 

[SuperSl0w]

The firmware Tomblarom shared in https://www.endless-sphere.com/forums/viewtopic.php?f=28&t=100064&p=1593956#p1591048 fixed the PAS/throttle problem on three of my controllers, HW 1.5

My current bbshd controller is broken, no pedal assist anymore, throttle works perfect. Changed pas sensor, no Bueno.. Now I'm looking for a new bbshd controller, but which type nr should I buy in order to flash this firmware?

My current bbshd controller is a 1-80-502. (1.4) so I can't flash the Tomblarom firmware, because that's 1.5.


I'm looking to buy: c769-51-501 controller, hopefully it's 1.5

 

[Bigworms77]

So I've seen several post in regards to pas sensor disabling. From my own knowledge I just removed the pas magnet from inside the casing by just removing the C clip and sliding it off. So easy to do and whilst I was at it greased both sides of the thrust bearings. I saw several post stating to cut the Grey wire but then you drop the resale value of your motor by doing it as someone else has already pointed out and really if you own a mid drive you should already be accustom to taking your side cover off and cleaning the old grease out every few weeks if you ride alot. Then re-greasing it

 

[SuperSl0w]

The firmware Tomblarom shared in https://www.endless-sphere.com/forums/viewtopic.php?f=28&t=100064&p=1593956#p1591048 fixed the PAS/throttle problem on three of my controllers, HW 1.5

My current bbshd controller is broken, no pedal assist anymore, throttle works perfect. Changed pas sensor, no Bueno.. Now I'm looking for a new bbshd controller, but which type nr should I buy in order to flash this firmware?

My current bbshd controller is a 1-80-502. (1.4) so I can't flash the Tomblarom firmware, because that's 1.5.


I'm looking to buy: c769-51-501 controller, hopefully it's 1.5

Ok. I bought This BBSHD controller: 48V1000W C769-51-501 https://www.aliexpress.com/item/32852258944.html
Photo of the received controller: https://i.imgur.com/6T5nhss.jpg

I had some issues with my BBSHD motor, so i did flash the controller straight away with firmware before i tested the original firmware.
Flashed: CRR10E4830E105027.1_(latest)_190927.bin provided by Tomblarom: https://www.endless-sphere.com/forums/viewtopic.php?f=28&t=100064&p=1593956#p1591048

No Throttle/PAS problems!!

 

[BBSV10]

I can confirm I tried the firmware changes on the page linked and this did not solve the throttle issues for me.

The only solution I have found is by disabling PAS with software settings. And just using throttle as needed.

I have attached a snap of my settings. Note you can play around with PAS settings to adjust max throttle on each level. The most important one I found is.

On basic tab: Make sure assist 0 is limited to 0 current and 0 speed.
On pedal assist tab: change designated assist level from by display to 0.

This relies on the fact that I have no throttle response on PAS0

This has made the BBSHD usable. Would be nice to have PAS. But at least I have smooth throttle and can pedal as needed without jerking around. (also I don't have to pull the motor apart which is a plus)

Hope this helps.

I’m also having the dreaded throttle/PAS issue on my new bbs02 setup.

I have an eggrider v2 and did the PAS settings above for my “offroad” map and it works great for using throttle and manual peddling together. No more jerkyness! Then for my other “road” map I disabled the throttle and have it set for just pedal assist. So just another option for anyone who is scared to solder and add the transistor.

Thanks for the help!

 

[dweebur2]

Hello.. I don't know if this has been covered. If so I apologize. I have the dreaded pas override of the throttle. What I've discovered was if you push the "-" button to put the motor into walk mode while you are riding, this will disable pas mode allowing you to use your throttle without interference. This will remain disabled as long as your pedaling. Once you stop pedaling and restart, pas will engage again. I find this very useful.