ongoing problem with lishui/xiongda set up

[handbaked]

Hi

I still have a dead e-bike (after several months now). Partly due to no time, work and my first child(!) and secondly because it is my first e-bike set up and I'm still trying to work it all out!

To re-iterate I have a Xiongda 2 speed motor, a Lishui 48v controller and C600 LCD. It was all working fine. I decided to rebuild the whole kit on a brand new frame/bike and then it stopped working ever since.

I turn it on and the LCD flashes Error 9.

I have been in contact with Bonnie at Xiongda and she has been as helpful as possible but I am still not getting to the conclusion of what the problem actually is. Initially she thought it might be the motor, she has even offered to pay the cost for me to return it to a german supplier, send me a new one from china and pay my wheelbuilder to rebuild the wheel! I really couldn't ask for more... other than clarification it is actually the motor at fault!

She asked me to run all the tests found here: http://www.ebikes.ca/learn/troubleshooting.html

I have done so and the tests for the 'blown mosfet test' and 'throttle test' are shown below:

BLOWN MOSFET TEST:

Green + Black = 1
Blue + Black = 1
Yellow + Black = 1

Green + Red = approx 700
Blue + Red = approx 700
Yellow + Red = approx 700

THROTTLE TEST:

Black + Red = less than 0.5v DC
Black + Blue = 0v DC

From these tests does that indicate that the controller has issues?? If so, the obvious thing to do would be to change that first and see if that solves the problem. If that is what you guys would recommend do any of you have a spare controller suitable for my setup that I can buy and have posted to me asap?

It has been far too long that this bike has been out of action. I have built a lovely bike that I know is going to be ace when working and its killing me not being able to use it for my commutes (almost literally!).

Any help greatly appreciated.

cheers, Tom

 

[wesnewell]

The throttle test indicate a problem with the controller throttle circuit assuming you checked correctly. It could be the controller on/off switch is off, or not making good contact also. You should have close to 5V on the power leads to throttle and with throttle full, about 4.1V between the black and the sense wire.

 

[handbaked]

thanks for the reply.

I put a multimeter across the ground and positive cable and only got 0.5v. When I was across the ground and the signal wire there was no reading no matter what the position of the throttle.

does the mosfet test indicate problems in your eyes?

thanks.

 

[wesnewell]

As long as the 1 was on the left hand side of the display, there was no continuity. If it was 1 ohm resistance, then that's a problem. My guess would be either the controller on/off switch is bad or the controller throttle circuit is bad. Rereading your post I see you have an LCD and have an error on it. Suggest you find the error codes for it. I'm not familiar with your system.

 

[fechter]

The throttle readings don't look right. There should be 5v between two of the wires. You might try tracing the throttle cable and look for a short. You could try unplugging the throttle and measure the wires coming out of the controller.

 

[handbaked]

i will try measuring it with the throttle unplugged and see if there is 5v coming from the controller. however, the error code 9 is pretty ridiculous as it pretty much means "there is something wrong". its totally non-descript.

 

[handbaked]

As long as the 1 was on the left hand side of the display, there was no continuity. If it was 1 ohm resistance, then that's a problem. My guess would be either the controller on/off switch is bad or the controller throttle circuit is bad. Rereading your post I see you have an LCD and have an error on it. Suggest you find the error codes for it. I'm not familiar with your system.

the 1 was on the left meaning no continuity. is that ok for all the phase wires against ground and the resistance of 700 for all phases against positive?

there is no on/off switch on the controller.

the error code #9 is totally non descript, it just means something is wrong! pah.

 

[wesnewell]

many times, the controller on/off switch is not on the controller, but is 2 wires connected to an external switch. And some controllers, like the ones I use just have a single wire that needs to be connected to battery positive to turn the controller on, either direct, or through a switch. I hook mine direct since I unplug the battery when I stop riding.

 

[handbaked]

many times, the controller on/off switch is not on the controller, but is 2 wires connected to an external switch. And some controllers, like the ones I use just have a single wire that needs to be connected to battery positive to turn the controller on, either direct, or through a switch. I hook mine direct since I unplug the battery when I stop riding.

fair enough, but this kit was working perfectly exactly the way it is wired right up until i moved it all on to a new frame and build...

 

[fechter]

Could be a wire got pinched somewhere or one of the connector pins backed part way out of the shell. The connectors are likely fail points.

 

[craiggor]

Could be a wire got pinched somewhere or one of the connector pins backed part way out of the shell. The connectors are likely fail points.

I was going to say this, when this was posted on the pedelecs fourum.I'am no expert and I have KT lcd3 on mine the errors only go up to 6.error 9 on yours says display connection fault.

 

[handbaked]

thats a valid point. i will check all the connections (again). need this beast on the road!

 

[handbaked]

Well i have got the bike out. Checked all connections and they seem to be fine as far as i can see. Totally going round in circles with this.

Bonnie has now asked me to return the controller and lcd along with the motor to a German contact of hers to check its working nature. Pffftttt

 

[handbaked]

Decided to order and pay for a new contoller and lcd from bonnie. This way i will have spares which will be a bonus, i can do a comparison to the lishui setup and if it fixes the problem i can avoid having to dismantle my wheel to send the hub motor and then pay to get it rebuilt again.

Fingers crossed this is going to solve the mystery...

 

[handbaked]

Ok just to end this thread the problem was the lishui controller. I think it died after having quite high (for its specs) current being drawn through it for a prolonged period of time. I got sent a kt controller and lcd by bonnie at xiongda for free and that has fixed it. Back on the road!

I would say that the lcd is nocer than that supplied with the lishui controller as this specifies wattage in use which is handy to tell how much the engine is working.

 

[miro13car]

High current drawn for prolong time?
Pretty prim7tive, cheap design I would say,no overcurrent protection?

 

[handbaked]

No idea to be honest. But yeh not exactly a great amount of time that it lasted!