Sabvoton Mounting

marscortes

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Hello everyone, new here.

My sabvoton controller needs to be mounted outside of my frame due to the body holding a 54ah battery. Was wondering if you all know if the phase wires and battery wire that are exposed to the elements ok to get mud or water on them. The picture attached is an example on how my build is going go. Any suggestions are appriciated. Thank you !
 

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Connectors, if not waterproof, will be the largest problem. Good waterproof connectors, properly installed, will help prevent connection issues between the controller and the rest of the bike, even if exposed to the environment. Which connectors you need depend on what signals you have, and the power levels you have to deal with.

The entrance of the wires into the controller, and the controller itself, if the controller is not potted, can be a problem. If all the wires enter the controller from one end, putting that end on the bottom may allow any water intrusion to exit without contacting anything inside the controller, as long as there is sufficient space between that point and the stuff inside to contain any water and there isnt' any splashing inside from vibration, bumps, etc. Having them on the top like in that picture means that any water that does get in thru the wire grommets is likely to accumulate inside and damage the internals.

Sometimes, with "sealed" devices (which are rarely actually sealed fully, as in IP67 or better) that don't fully keep out water, but are never actually being submerged, it is helpful to add a tiny drain hole at the lowest point to let out whatever does get in there. It depends on your specific weather/etc conditions, and usage.

If the controller has any bolt-on connections on the outside (phase, battery, etc), or exposed connector junctions at the body, you can try using dielectric grease on the connections, inside the connectors, and outside them, to help minimize water intrusion.

Wires themselves, if insulation is intact, are generally ok with environmental exposure, though sunlight (UV) will degrade the insulation over time, so a "jacket" around them is helpful for that.

The jacket, if tough enough, can also provide some measure of protection against impact and abrasion on the wires. If a lot of this is expected, I'd recommend a hard casing around the wiring and connectors to prevent damage.
 
Mounted in that location, you will need it to be covered.
One of the main things that will happen, is the controller will be sprayed with water and dirt by the front wheel (whether is is raining, going through puddles or off road).
That frame I believe comes with a controller cover, but you cannot use it with a Sabvoton as the controller is too big.
Your best option is to make a new cover that will fit.
I did similar to my build (Sabvoton 96120) and made a 3D printed cover (In interlocking parts, as printer not big enough for doing it in one piece).
I am now at year 2 and about 8000km since build, with no problems at all, and the controller is as clean as when I first fitted it.

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Thanks for the input guys. I did a search on a shroud or cover with no avail. I do not have a 3d printer nor am I buying one for this purpose. Maybe just hot glue some abs plastic together, not sure yet. I was thining on mounting the controller under my seat. I have seat that I purchased from CAB motorworks. I dont know how hard it would be to rout all thost cables through, or if it would even reach. :shock:
 

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marscortes said:
Maybe just hot glue some abs plastic together, not sure yet.
Don't use hot glue. If you use ABS, there's a glue called Plastruct that will bond ABS to ABS very thoroughly, with only enough to run down between the pieces, if they are cut well enough to fit right up against each other. (if not, you can sand them against something flat like a sidewalk until they are flat enough to sit right against each other with no gaps).
One example:
https://www.amazon.com/Plastruct-Plastic-Weld-applicator-Bottle/dp/B00FDFWJD8
If you find a smaller bottle, you could probably do it with less than 1oz, but the bigger bottle is probably cheaper. ;)
I was thining on mounting the controller under my seat
.

Under the seat can get splashed from the rear wheel (unless you have a wide enough fender to prevent it).
 
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