So I blew out my last controller by hitting a bump...
Now I started having some issues with my new one (no shunt mod and no 100V caps either). I'm running at 60V, but saw similar problems when i went back to stock 48V. Basically, if I hit a sizeable bump and then hit the throttle some weird stuff occurs. The motor seems to miss. I also noticed that the voltage gauge plummets. It's a bit scary because this is exactly how my last controller died and that ended with me pushing the bike 8 miles.
I'm just wondering if anyone had any thoughts or had seen this before. My initial feeling is that something is shorted and hitting a bump is causing something in the power lines from the controller to the motor to short to the chassis. That would certainly explain why the voltage meter plummets for a second. A huge amperage spike would cause the battery voltages to sag immensely. I have an ammeter installed, so I'll try to catch a reading on that the next time it happens. Note that the 30A fuse hasn't burned out yet either.
My other thought is that hitting the bumps is causing a problem with the hall sensors in the motor. That would be affirmed by the fact that the motor will seem like it only sags the voltage/misses every other cycle or so. Though, thinking about it, the hall sensors would cause 1/3 of the revolution to miss, not 1 part in every 2 or so revolutions.
I checked the hall connector from the motor to the controller and made sure it was tight. I also wrapped some tape around my 3 power lines from the controller to the motor hoping (where the bullet connectors are, since the green insulation looked a bit blackened) that will prevent any shorting. We'll see how riding goes tomorrow.
An update...
So the problem persists. I checked the amp gauge when the voltage plummeted and there's no amperage moving in the battery string. At this point, i'm wondering if one of the batteries is dieing/flaking out already. To make matters worse, when I pulled into work, the bike decided to get really strange. The motor barely turns. When I turn the key to on, the power shoots up to full voltage then immediately starts dropping towards empty.
I'll do an equalization this weekend and see if anything is going wacky with the batteries.
I just got my scooter 5 days ago and it just started doing the same thing today... What gives? it was going 37kmh now its only going 24 after hitting a couple of bumps in the road.and I've only ridden it like 4 times and only once more than 5 miles. I was planning on doing the shunt mod and now don't know if I should. or if I should wait??
IF ANYONE HAS ANY SUGGESTIONS PLEASE HELP!!! I USE THIS TO GET TO WORK!
Does your bike a high/low speed button beside the throttle like mine does? Maybe you accidentally activated the speed limitter.
Just a thought.
Any other symptoms besides reduced speed?
You might want to check the connections as a new vehicle things might have simply come loose.
I always look at the easy stuff first.
Grandpa Chas S.
I checked all the connections and nothing is loose. I got it to fluctuate between 15-18mph but it was going 23mph originally, and all I can think of is when I hit a few bumps in the road today, didn't think they were anything signifigant. Ordered a new controller box from extreme, 2 new batteries so I have one normal spare and one modded to 60 or 72 volt. Just wanna get this problem fixed before I start doing ANY modifications! Any help would be greatly appreciated.
Andrew
Gas Free in Daytona Beach!!!
Connect a voltmeter to your batteries. If its low you have a bad battery or connection (assuming your charger is working). If you have full voltage at rest, keep it hooked up and start driving. If you see a large voltage drop check your batteries/connections. If voltage looks good then it may be a problem with the controller/motor/wiring.
Update: Ok so I went on my 15 mile journey this morning to work and it took me an hour and 15 minutes. it said I was going 15mph but guess its off a little. then miraculously while on a smoke break at work I tried fiddleing with it and it "apparently" is the throttle grip is sliding off the handlebars and when I hammered them in with my hand it went all the way up to 27mph with no modds on my scooter! Praise almighty that made the rest of my day at work so awsome! This speed however was while on the stand not actually me ridding. But amazingly when I ride it seems to be the exact speed as on the stand and I weigh 210lbs so go figure. rode all the way home at 23mph and tested before I left work at same speed. cant get same speed though would wonder if a different throttle would meke this go alot faster without having to do any 60 or 72 volt modds??? any suggestions? I think the "governor" might be part of the throttle?? And thus by switching out the throttle with another for a higher rated bike might make this bad boy go sonic?? Im not that great at trying new things mostly cause of laziness but anyone out there feel like putting this to the test? I've heard that zerogas has gotten these things [retty figured out and would definately like to hear some feedback from him on this! But for now im riding gas free in Daytona Beach with a suspended license and flippin off the gass stations as I pass with the $2.62 a gal! :)
Thanks for all the help so far, I might need more if this isn't the only problem.
FuctUpG,
A.K.A.
Andrew
In my case it looks like my extra battery (the one that brings me to 60V) is failing. I'm going to see if i can return it, as I've had it for a whopping 2 months, so I think it was just a poorly built battery.