My trike came with a Bionx PL-350 (350 WATT) system. I had nothing but trouble with the Bionx system.
I blew the MOSFETs inside the motor THREE TIMES! First two times were under warranty. Third time it was out of warranty and it was my baby. I did this by blasting downhill and when I hit ~42 MPH it appears the back EMF from the motor exceeded the breakdown of the MOSFETS. Result? Little pieces of what once were functional MOSFETS rattling around inside the motor. This appears to be a design flaw of the earlier Bionx systems. I don't think they thought anyone would be doing that kind of speed and didn't design the system to withstand that kind of back EMF from the motor windings.
At this point I had enough of Bionx and refused to pay their ridiculous prices for replacement parts. To make a L-O-N-G story short, I scrapped the battery, control system, gutted the motor and brought out phase and hall sensor wires. I built up a 60 V 28 AH Li-Ion battery pack and connected the system to a $25 12 MOSFET BMS Battery controller (http://www.endless-sphere.com/forums/viewtopic.php?f=4&t=13691). Although this controller comes in two versions (36 and 48 volt) I took it to 60 VDC after checking the rated voltage of the MOSFETS and capacitors. The Bionx motor runs perfectly in the sensorless mode using this controller so all you really have to bring out is the three phase wires.
I've been running this system now for about a year with absolutely no problems. The BMS Battery controller comes with the internal current limit set to 25 amps. This means at 60 volts I am pumping around 1500 watts through the Bionx 350 watt motor. Cruising speed is now in the 32 to 35 MPH range instead of the wimpy 20 MPH I used to suffer with the Bionx system. The motor is mounted in a 20 inch rear wheel using a 20x1.75 inch knobby tire. If I pedal along with the motor 40+ MPH is no big deal on level roads. It does 20 to 25 MPH up the steepest hills in this area with no overheating issues. I have no doubt this motor could take at least 2X the 1500 watts I've been dumping into it as I've inspected the windings and so far nothing has discolored after running it for a year at the 1500 watt level and I have a habit of running the throttle wide open most of the time which results in the system running at the 25 amp current limit especially when climbing hills. I live in the foothills of the Allegheny Mountains (peaks 3100 ft. above sea level). I've been pretty much gas free for the past 6 years and put around 5000 miles a year on this trike so it's seen a LOT of use. I routinely haul as much as 100 pounds of groceries as i do all my shopping and running around town on this trike!
I was just about to post a HOW TO article for those that are fed up with Bionx and their ridiculous prices when I ran across this topic. I still intend to publish my mods when I get a few more photographs together.
PS - Regen also works fine using the Bionx motor with the BMS Battery controller.
More photos at: http://k3pgp.org/bionxboard.htm
^^^ Logging is done via a bluetooth module installed inside the Cycle Analyst and connected via bluetooth to an HP IPAQ RX3115 pocket computer writing to a file using my GPS software. Hence the .NMEA file extension... Battery voltage sagging a bit as this was the last part of the trip home after a round trip of ~30 miles.
Freewheeling speed (back wheel up off the ground) is approx. 37 MPH at 58 volts using a 20x1.75 inch knobby tire which will give you some idea of the turns / volt ratio for the Bionx 350 watt motor.
Please note: All of the above applies to a Bionx PL-350 bought 3 or 4 years ago. Hopefully the newer Bionx systems do not have this fatal (EXPLODING MOSFET !) flaw...