BBS01B 36V 250W - trying with higher voltage [success]

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fechter   100 GW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by fechter » Jun 11 2019 4:58pm

Band end away from the display.
"One test is worth a thousand opinions"

RayGo1   1 mW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by RayGo1 » Jun 16 2019 12:36am

Thank you fetcher! :D

The TVS diode did the trick. It turned out to be a fairly easy fix for the HVC limitation of the BBS02 36v 500w mid-drive system. Anyway, I installed a TVS diode with a 6v breakdown voltage as recommended using a display extension cable.

So I charged my new 36 volt li-ion battery to 49.8v or 4.15v per cell. I hooked the battery to my bike and got 49.5v on my voltmeter. The voltage was 47.3v on the motor side of the TVS diode and 40.6v on the display side. That gave me a 6.7v drop and no Error Code 7. My LVC is 32 volts leaving my battery at a safe discharge voltage of about 38.4v or 3.2v per cell. I have no BMS on my battery pack. The higher voltage is giving me a "peppier" response. I have all 9 PAS settings programmed and I used to do most of my ride on PAS 3. Now PAS 2 with this li-ion battery feels like PAS 3 with my old lifepo4 battery.

So the fix cost about $20. The extension cable cost $10 and the Vishay TVS diode, ICTE5-E3/54, only cost 60 cents but the shipping was $8. I expect to give this setup a good test ride shortly.

Wizzeros   1 mW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by Wizzeros » Jun 16 2019 5:01am

RayGo1 wrote:
Jun 11 2019 3:51pm
Thanks for the link.

I ordered several TVS diodes with breakdown voltages of 5v, 6v and 7v to experiment with. Since these are unidirectional diodes, which way should the band on the diode face? Towards or away from the display?

Thanks again for the help. Hope to have results shortly.
Hello RayGo1,

Not sure right now about the polarity, but if you make a mistake it's relatively easy to just rotate the diode. Reversed polarity didn't brake down any diode in my case, but later on I bought bidirectional ones to save some time on assembling. Below I add how it looks in my case. Universal PCB, cheap switch, no heat sink, no enclosure - still works fine.

EDIT: I didn't notice your last post. Congratulations! Because I also could not fully discharge my batteries using only one TVS diode, I added another one and a switch, to decide on the voltage drop I want to get. However, I do have a BMS connected to my battery, so it never lets my cells to discharge too much regardless voltage level on the display. I also add thermal camera photo of my bike. TVS diodes (near the steering tube) are getting hotter than the frame, but heat level is less than 30 degrees Celsius in this case. The bike was accelerating and braking only for several minutes before this photo was taken (my friend was testing it for the first time). I don't think it gets much hotter though.
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RayGo1   1 mW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by RayGo1 » Jun 17 2019 12:43am

Thank you Wizzeros for the info.

I tried to keep it simple. I moved the brown wire and TVS Diode outside the cable to keep it away from the other wires due to possible heat concerns. I then covered the diode with heat shrink wire wrap. I ran this setup for about 15 minutes with no detectable heat problems. I'm guessing the temperature was about the same as yours at about 90 degrees. :bigthumb:

TVS Diode Fix.jpg

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fechter   100 GW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by fechter » Jun 17 2019 10:20am

RayGo1 wrote:
Jun 17 2019 12:43am
Thank you Wizzeros for the info.

I tried to keep it simple. I moved the brown wire and TVS Diode outside the cable to keep it away from the other wires due to possible heat concerns. I then covered the diode with heat shrink wire wrap. I ran this setup for about 15 minutes with no detectable heat problems. I'm guessing the temperature was about the same as yours at about 90 degrees. :bigthumb:
That looks like a great setup. Those TVS diodes can handle pretty high temps.

In the FLIR pic, the seat looks warmer than the diodes.
"One test is worth a thousand opinions"

ghill13   10 µW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by ghill13 » Dec 12 2019 12:19pm

I this was posed a while back but I was wondering if you could do a quick how-to on this? Where did you put your diode? Maybe even a picture or two of the section of cable where you put the diode.

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by ghill13 » Dec 12 2019 12:21pm

whoops I see the pictures now. I just need to go do it ha ha

Maxid   100 mW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by Maxid » Dec 19 2019 1:12am

RayGo1 wrote:
Jun 16 2019 12:36am
So I charged my new 36 volt li-ion battery to 49.8v or 4.15v per cell.
Just to correct an error that might be very dangerous if a beginner reads your post:
A 36V battery is a 10S system with 42V fully charged. RayGo1 probably uses a 12S system with a 43.2V battery (50.4V fully charged).

1boris   100 W

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by 1boris » Dec 21 2019 9:02am

Can I use an eggrider lcd to run 48volt on a 36volt bbs02?

Grassgirl   1 µW

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Re: BBS01B 36V 250W - trying with higher voltage [success]

Post by Grassgirl » Feb 13 2020 11:52am

As a woman trying to fix my bike can you tell me do I solder the tvs diode on ?

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