I am new on this nice forum. I have a big problem with my 1 year old Bionx System. It´s a PL500HS.
A few days ago while I was riding on full charge, the console display started blinking and the motor stopped assisting so when I checked out the connection from the batt to the motor I noticed it was a bit loose. When I tried to plug them back I could see a minor spark coming from the connector. After that spark, the system could be turned on and off OK and recharged but the motor doesn´t communicate with the console anymore and the speedometer, odometer, doesn´t move from 00km/h.
The firmware revision is REV 2:3
I did full reset and checked out all connections. On
diagnostic MODE you get the following strange reading: off / 5541.3/ ERR/ 40. When I turn on the system I hear 3 beeps.
Today I tried the diagnostic mode again and the figure I could see on the left
hand side under the 2 big zeros and underneth the word batt was:
5540.5 for two seconds, then it changed to ERR and then to 40, both for one second.
The DC/DC battery connector suplies 6V Ok to my lighting system, so the battery seems to work fine but the motor doesn´t assist or brakes anymore. To me it seems like it could be some kind of fuse that if replaced may solve the problem?
I explain all that in detail just in case there is something you know I can do myself as I live in Europe and I bought it from Canada so sending it back again would take too long and shipping is too expensive!
Thanks very much for any advice.
I know nothing about bionix. this post is to bring your post to the top of the page.
Be the pack leader.
36 volt sla schwinn beach cruiser
36 volt lifepo4 mongoose mtb
24 volt sla + nicad EV Global
I can't seem to find any reference to the fault codes. I think you need to contact the manufacturer.
In the EV Download Library there is a BionX Diagnostic manual which might help some. I would clean all of the connectors with isopropyl alcohol (same as rubbing alcohol).
[url=/forum-topic/motorcycles-and-large-scooters/587-my-kz750-electric-motorcycle-project]KZ750 Motorcycle Conversion[/url]
[url=/forum-topic/motorcycles-and-large-scooters/588-fixing-my-chinese-scooter]900 watt scooter[/url]
Pic from http://www.electri
I own a Bionx. There are two connections between the battery and the motor and one between the battery and the controller. I assume the spark was the 2-wire, thick, power cable between the battery and the motor, yes? I'm not wild about the alcohol idea, but I would check all the connections especially the data wire between the motor and the battery. Maybe it got knocked loose when you were fiddling. The speedometer should work whether the motor is working or not. If it's not then the controller isn't getting any data.
Three beeps are normal for a system startup.
I haven't seen any user replaceable fuses, but there really should be some.
I like the idea of downloading the trouble-shooting manual and I like the idea of contacting the manufacturer.
"we must be the change we wish to see in the world"
Yes you are right the spark was on the thick connector between the motor and the battery. I have checked all connectors and they seem to be ok. It seems there is not communication at all between the motor and the system. When I turn on the console there is not countdown on the speedometer. I believe the manufacer should have integrated a external fuse on the main cable as it is the case on ham radio transceiver, so in case of any electrical shock, that helps very much and is the first place to stop the problem and prevent any damage to the rig. The speedometer doesn´t move at all and there is no assisantance nor reg. brake. I have contacted the manufacter and after a long conversation they have suggested to send the whole system back to the dealer for repair and that is what I am going to do next week...Even that is gonna cost me a fortune to pay the sipping from Europe to Canada and then all the way back through customs and so on... :-(
I was also wondering if it had something to do with the fact that I used the regen brake going down hill with the battery on full charge the day I left home and came back with this problem...
Thanks for your comments and suggestions!
I have no idea whether it is your particular problem, but I ran into a guy recently who represented himself as knowledgeable about things electric and he specifically said that doing alot of regenerative braking in a system with a fully-charged LiPo battery can cause problems.
The battery is a Li-ion, not sure if that makes any difference. If the use of the regenerative braking may cause damage to the system to that extend I guess the manufacter should prevent the customer in the way they should use it and there is no mention at all anywhere on the users manual.
This is correct. If a system is not designed for using Lithium Ion batteries then regenerative braking can cause damage to the batteries by over-charging the pack. The real question is "Is the regenerative braking regulated so it will not over-charge the battery pack?"
If the manufacture just switch battery chemistry, like Bionx did, they may not even be aware that their regenerative system may over-charge the battery pack causing the battery life to be cut short. In this case they would not know to give the consumer a warning. If there are any Bionx dealers reading this site please answer this question for us.
Grandpa Chas S.
chas_stevenson [at] yahoo.com
This is an intersting issue for us Bionx users. However my Li-ion battery apparently continues working well. It keeps the charge, I can plug my 35W halogen light system to the DC/DC connector and it works fine...What I mean is that the only problem is the lack of communication with the motor. I think there is no problem with the battery itself and what it seems to be damaged is the electronics between motor and batt. would it be perhaps the controller or some kind of internal fuse?
The controller isn't a bad bet. A voltage surge could take it quite easily. I don't know about fuses. The battery case unscrews easily and you can check for yourself. That's where they'd likely be lurking.
"we must be the change we wish to see in the world"
I have a friend who might help you. But you have to be a little patient. He's coming out from a Alcohol Rehab, but I assure you that he does a great job with his hands and mind! Contact me if you still need any help.
There is for sure a fuse in the battery case. See photos on this french site.
hope it helps !
I believe I know what the problem with the battery spark is.
Is this a continuing problem?
Hi everyone!! Thanks very much to all of you for your answers. I finally had to send the whole system back to Canada to the dealer where I got it from, and he sent it to Bionx to have it fixed since it was still under warranty. It seems it was a problem with the motor so they just sent me back the system with a new motor which has been working OK since then. However I found a new problem with this new motor which I haven't paid much attention to so far: When setting the alarm system on, it does not activate the regen mode anymore when I turn the wheel. When you turn the rear wheel a few times, it just beeps sometimes, not always, but without any resistance...Any idea about how to solve that?
I must say quite honestly that even though I like the Bionx system very much and I really enjoy it, I found the after sales service not reliable and the product itself quite irregular.
What do you mean exactly by that?
That the product you currently own is inconsistent performance wise?
That they seem to have perfect working unit and other unit that don't work at all?