EVG Global 24v ebike controller failure - help please

[Davets]

Hello I have a 24v Lee Iaccoca EVG that I'm trying to get working.
I know most people here say the 24 volt model is way too slow, but now that I've got the parts together, I'm trying to make it work.
I have a stock controller and 2 12v 12ah SLA batteries. I hooked it all up and it made the normal beeps, showed green charge on the throttle, and worked for a spin around the block.
Unfortunately that's about as long a it worked. I can't figure out for the life of me what's wrong now. Battery shows 24volts output on voltmeter, I opened up controller and don't see anything obviously wrong with it... After it stopped working and I disconnected the battery, then reconnected it, at first there was a click, like a relay closing, but now nothing, Any thoughts on what else to check or repair? I have a volt/ohmmeter and a rudimentary knowledge of electronics. Is my 12ah battery pack too many amps? The specs from the original 24v bike specify 2 12v 12ah SLA batteries and that's why I went with those.

Any help from all the EVG gurus out there much appreciated!

Happy to post photos if there's anything specific that would help in the diagnosing process.

 

[dogman dan]

I don't know much about the original electronics on an EVG. Mine had that all gone when I got it.

But the 24v version does have a temp switch in the hub. That's the two tiny wires going into the hub. It may be that the same wires go through an on off switch, that could be at fault. That circuit opens when the motor heats up too much, and open, it shuts off the controller.

So the first thing to do, is look for a cut in those wires. One of them cut would shut it off. Or maybe the switch ( if there is one) is just gunky.

Really fried brushes would overheat the motor fast, or just stop working. Test the bare motor by simply hooking 12v battery to the main wires. If it spins ok then, its not the brushes.

 

[dnmun]

power it up and look for 5V on the throttle. if you want to get help you have to provide pictures of what you are asking about since nobody has a clue what you are talking about otherwise.

 

[Blackssr]

http://www.ebay.com/itm/Ebike-24-volt-controller-for-Lee-Iacocca-s-EVG-Electric-ebikes-/231197508799?pt=LH_DefaultDomain_0&hash=item35d47204bf

 

[Davets]

Dogman, I really appreciate your thoughts. The motor seems to be fine and runs if power is applied to it directly. But while I understand what you're saying about the temp switch in the hub, I font think that's the problem, since the controller as a whole seems not to redpond properly as it did when the bike worked properly the first time.
So I did a little more research. . . The controller makes a click like relay closing when I connect the power. But it seems to do nothing more than that. Here are a few photos of the controller, from outside, and taken apart. Any thoughts on what might be wrong much appreciated. Otherwise, if I go with an aftermarket controller and throttle, any advice on a reliable unit at a reasonable price?
And Dogman or others, do you know what the bolt spacing on the chainring is if I want to go with a bigger one?
Thanks for the help!
Dave

 

[dnmun]

you don't have to speculate. it is a DC brushed motor so a continuity test would show you right away if there is an open circuit in the motor.

did you ever look for a 5V signal on the throttle?

 

[dogman dan]

Motor is fine then. But the heat switch circuit must be connected to make the controller turn on. Try jumping it where the switch enters the controller. Find where the switch wires go in, and then make a connection right there. See if that turns it on.

I can't help you much with the controller. Like I said, on mine it was long gone when I got the bike. Test throttle function would definitely be the next step.

Sure the battery is charged fully? 24v is just about finished. should be 26v-27v full.

 

[sharkmobil]

Test your brake connections, look at sensors, should be no continuity when idle (lever not pressed).
Both of them inhibit controller's output when applied (continuity). If nothing works contact me directly, I might have a spare 24v controller on the shelf.

 

[Davets]

Thanks for the replies, guys. There was no voltage at the throttle and I decided to forgo the stock controller even though I was disappointed to see the stock goodies (horn, etc) go. Based on kauaikit's posts and experience, I ended up going with a cheap brushed motor controller and throttle from electric scooter parts .com and over volting the stock 24 v heinzmann motor to 36v. While this is not a super fast setup, it works well so far and I am enjoying my fist (very cheaply built) ebike.