Hi all,
First I want to note that there is no BionX shop in my country and as the set is out of warranty, so I don't have the option to service the set with BionX technicians.
For the last couple of months I am dealing with very annoying issue with my BioniX set:
It works, but sporadically (recently more often) the speedometer starts showing 0km/h and the assistance/regeneration just stops. Then without clear reason starts again. Sometimes after a minute, sometimes after a day, which obviously makes the set unusable to me.
My set is early model, but is CAN-BUS one and I think is 350/250W version ( as it is bought from EU it should be limited to 250W as such are the regulations). The battery is 36V Li-MN and the set is only 2000 kms old and the battery charges well and holds up enough capacity to go for 35-40km at assistance level 4 on flat ground (when it works).
When the issue appears and assistance stops I go to 3772 and what I see is 5541 and then it changes to Err 40 which I read as: 41V battery voltage and errors 40 and 55 (problem in the connection between the console and the battery and problem in the connection between the console and the motor).
What I did troubleshooting so far:
1st: I checked all the wires with an Ohm meter. All had readings so I supposed that they are fine.
2nd: I replaced the console as the only variable that appeared in both errors- it was with newer software and worked for several days without problem and then the issue re-appeared.
3rd. I bough a new bracket with all the cables, so I can be sure it is not a problem with them (nevertheless I tested them with the ohm meter)- that did not help- the issue reappeared the same day.
4th. I disassembled the battery case and checked the battery's BMS for blown fets and cables etc- no visible damage was noted- so I re-assembled it.
5th. I decided that the issue should be in the motor(or the motor cables-the ones that go out the hub) - the reason to think so is that I was left with only this part of the system unrevealed and because I read about a guy with the same errors 40 and 55 which were resolved by sending the whole set to BionX and replacing a faulty motor by them. Another reason was that I randomly were hearing clicking noise from rear wheel and as I inspected all my gears and parts and did not notice anything else. So I disassembled the motor using some huge Allen keys as a L-shaped levers to pray the two lids open, a car suspension joint extractor bracket to pull the special bionX bushing and a hydraulic press to press out the stator from the right lid(the magnets were holding it unbelievably hard).
I noticed some signs of rust on the magnets and oxidation on the hall sensors' legs, but nothing else looked wrong. I haven't carefully inspected the strain gauge as it is covered with some kind of silicone that I haven't removed yet. There is definitely no blown MOSFETs and a strange thing is that I have twice more MOSFETs comparing to pictures I've seen, and half of mine have only one leg left and the others are cut(probably the circuit board is used for more powerful versions of the same motor).
So my question is if someone here knows the system well enough to point to me what to measure and check, as I have the motor already opened and what could be the faulting part considering that it is happening occasionally.
If I don't find a solution I will lead out the hall sensors wires and will scrap the board so I can use external controller, which I am not sure how will end, but I am already frustrated by the closed system.
PS. I contacted BionX support and gave them the errors and my troubleshooting steps and after several advices from them to check connections and cables they send me the closest BionX shop locations abroad and said they cannot help me anymore without BIB.
First I want to note that there is no BionX shop in my country and as the set is out of warranty, so I don't have the option to service the set with BionX technicians.
For the last couple of months I am dealing with very annoying issue with my BioniX set:
It works, but sporadically (recently more often) the speedometer starts showing 0km/h and the assistance/regeneration just stops. Then without clear reason starts again. Sometimes after a minute, sometimes after a day, which obviously makes the set unusable to me.
My set is early model, but is CAN-BUS one and I think is 350/250W version ( as it is bought from EU it should be limited to 250W as such are the regulations). The battery is 36V Li-MN and the set is only 2000 kms old and the battery charges well and holds up enough capacity to go for 35-40km at assistance level 4 on flat ground (when it works).
When the issue appears and assistance stops I go to 3772 and what I see is 5541 and then it changes to Err 40 which I read as: 41V battery voltage and errors 40 and 55 (problem in the connection between the console and the battery and problem in the connection between the console and the motor).
What I did troubleshooting so far:
1st: I checked all the wires with an Ohm meter. All had readings so I supposed that they are fine.
2nd: I replaced the console as the only variable that appeared in both errors- it was with newer software and worked for several days without problem and then the issue re-appeared.
3rd. I bough a new bracket with all the cables, so I can be sure it is not a problem with them (nevertheless I tested them with the ohm meter)- that did not help- the issue reappeared the same day.
4th. I disassembled the battery case and checked the battery's BMS for blown fets and cables etc- no visible damage was noted- so I re-assembled it.
5th. I decided that the issue should be in the motor(or the motor cables-the ones that go out the hub) - the reason to think so is that I was left with only this part of the system unrevealed and because I read about a guy with the same errors 40 and 55 which were resolved by sending the whole set to BionX and replacing a faulty motor by them. Another reason was that I randomly were hearing clicking noise from rear wheel and as I inspected all my gears and parts and did not notice anything else. So I disassembled the motor using some huge Allen keys as a L-shaped levers to pray the two lids open, a car suspension joint extractor bracket to pull the special bionX bushing and a hydraulic press to press out the stator from the right lid(the magnets were holding it unbelievably hard).
I noticed some signs of rust on the magnets and oxidation on the hall sensors' legs, but nothing else looked wrong. I haven't carefully inspected the strain gauge as it is covered with some kind of silicone that I haven't removed yet. There is definitely no blown MOSFETs and a strange thing is that I have twice more MOSFETs comparing to pictures I've seen, and half of mine have only one leg left and the others are cut(probably the circuit board is used for more powerful versions of the same motor).
So my question is if someone here knows the system well enough to point to me what to measure and check, as I have the motor already opened and what could be the faulting part considering that it is happening occasionally.
If I don't find a solution I will lead out the hall sensors wires and will scrap the board so I can use external controller, which I am not sure how will end, but I am already frustrated by the closed system.
PS. I contacted BionX support and gave them the errors and my troubleshooting steps and after several advices from them to check connections and cables they send me the closest BionX shop locations abroad and said they cannot help me anymore without BIB.
