October 3, 20214 yr Author I shouldn't have bothered trying to get more lights on, but it was to be better seen by drivers, so it was worth a go. I think my controller is blown. The battery is fine, it's showing lights when I press the button on the side, and it's reading 37.5V on the multimeter, but when I connect it to the motor, nothing happens when I try to start it, using the power on buttton on the handlebar. I've disconnected the "group light adapter", but it's still dead. Time to buy a new controller? What can I check to attempt a repair, or verify that it's dead? Edited October 3, 20214 yr by guerney
October 4, 20214 yr Author It seemed to be going so well What electronic component(s) are most likely to get damaged if I, while soldering those 60A connectors, happened to melt wire insulation further down the wire, to cause a short circuit? That might have happened - I did hear a spark and a sort of quiet humming noise, while I was connecting and disconnecting things in panic, trying to work out why nothing was working. But it may have been caused by something else, such as that trash "Power module" I connected it to. Maybe I was in too much of a hurry - Tesco turned up to deliver groceries. Either way, it's a dodo. Maybe I should just buy a new controller? Battery seems to be fine. Edited October 4, 20214 yr by guerney
October 4, 20214 yr The controller is completely sealed with silicone, trying to pry it all off will cause more damage to components, you will likely not find the issue any how by looking. You may have shorted a mosfet for which you can try testing with a meter., one will need to remove the controller to do so to get at the wiring, also at the same time one can test the 5v line and the hall sensors via the wiring. That is really all one can do unless a true wiz at software pcb design.
October 26, 20214 yr Author The controller is completely sealed with silicone, trying to pry it all off will cause more damage to components, you will likely not find the issue any how by looking. The new controller has arrived and I'm about to take the old one off - is there any point in applying multi-purpose clear silicone around the connectors?
October 26, 20214 yr Author In my experience so far - this is a fantastic, cheap soldering iron for power cables: https://www.amazon.co.uk/Silverline-868784-Soldering-Iron-100/dp/B000O54PTI/ This is a very good flux, acid-free: https://www.ebay.co.uk/itm/164377527071? I'm waiting for this 4:1 marine heat shrink to arrive: https://www.ebay.co.uk/itm/203043868181? ...in the meantime, I'm filling my home with solder related smog, practicing... I'm getting better! Having the right tool for the job helps, and that 100W Silverline soldering iron heats everything up very fast indeed, after a 5 minute warm up to get up to temperature. I'm installing this waterproof motorcycle light switch for the three lights, which will connect via an inline fuse to the battery: https://www.ebay.co.uk/itm/163944201149? Edited October 26, 20214 yr by guerney
October 26, 20214 yr Author This cheap, adjustable wire-stripper does a great job (after a drop of 4 in 1): https://www.amazon.co.uk/Amtech-B4250-Superior-Stripper-6-Inch/dp/B004TRT19Q/
October 27, 20214 yr Author This Weller 60/40 flows beautifully: https://www.ebay.co.uk/itm/313697943878? Normal tin solder still beads a little, even with flux smeared over the joints beforehand. I've tested continuity using a multimeter, and have done pull tests on my many soldered wires - I think I'm ready! The 4:1 marine heatshrink, can't arrive soon enough...
October 27, 20214 yr Author IT LIVES!!!!!! I got there in the end! Thank you all for your help and advice. Now all I've got to do is add yet more self amalgamating rubber tape, to waterproof... then turn off this computer and ebike to work! The light on your right (my left) is controlled via the display, as is the rear red light. The light to your left (my right) is controlled by a waterproof motorcycle light switch on the handlebar (with inline 3A blade fuse), along with the third headlight on the fork. In addition to these four lights, I have two torches pointing forwards from the handlebar, and one on the handlebar pointing backwards at me flashing at my reflective hi-viz clothing. There are two more rear red lights, and I also wear a red LED flashing sash. I'm hoping that drivers notice me more often p.s. I'm about to order a spare controller because: 1. I'm bound to kill this one too! 2. It'll be Mad Max world soon! Edited October 27, 20214 yr by guerney
October 28, 20214 yr Author I was ebiking in continuous rain for four and a half hours today, which tested waterproofing, and I was carrying 62kg in extra weight for 48 minutes - 32kg in my rucksack, the rest in pannier bags... Nike trainers were full of puddles, but the controller worked great, and nothing fizzled out, electrocuted me or went up in flames. It managed all the hills at full power, just a bit slower because of all the extra weight. I had a panicked moment when I realised that the two lights directly connected to the battery via an inline fuse and motorcycle switch weren't working... then I realised I had accidentally switched them off when I almost toppled over at some traffic lights (hard to balance a bike starting off, with 32kg on your back and a bike which is 30kg heavier than normal, from a standing start on a hill), when a deafeningly loud motorcycle rushed past me, as the lights turned every so slightly more amber-ish. I'm starting to hate those guys... (present company excepted). Edited October 28, 20214 yr by guerney
October 28, 20214 yr Author why have you got 32kg in a back pack ? i cant stick 4 kg lol I've been growing veg all Spring and Summer during lockdowns - I won't need to buy any veg till April next year! I need a rucksack with better padding - carrying a lot of these really hurts!
October 28, 20214 yr I've been growing veg all Spring and Summer during lockdowns - I won't need to buy any veg till April next year! I need a rucksack with better padding - carrying a lot of these really hurts! [ATTACH type=full" alt="44556]44556[/ATTACH] You need a proper cargo bike.
October 28, 20214 yr Author wtf is that can i smoke it lol You can, but it'll make you "Low" I've got 26 so far... They keep without refrigeration till April. Bloody nice too. One is so big, I can't get it upstairs.
October 28, 20214 yr Author Halloween veg SW, just not very orange. These are for flavour - Crown Prince... the best tasting pumpkins that exist! Russian in origin I believe, and they usually sell for £30 each.
October 28, 20214 yr Author You need a proper cargo bike. I'm renting two gardens next year - twice as many of the things... This could get out of hand!
October 28, 20214 yr I'm renting two gardens next year - twice as many of the things... This could get out of hand! Like lights on your bike now you can solder, OCD.
October 28, 20214 yr a avg user will use 3.5g a week so 35 quid if i want 1kg it will be 6k https://herbiesheadshop.com/disclaimer
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