After 3000 miles, my aotema kit has died.
Symptoms before death.
1. Occasional loss of power. The power loss did not appear to be caused by bumps or turns or acceleration. I would be riding along and the power would just quit. Full throttle, part throttle, no pattern.
2. I was able to restart the system by unplugging the three wire motor connection. I did not have to turn off the controller or unplug the battery. I figured it was that controller to motor connection that was failing. Since new, the three wire trailer type plug has been a concern as it gets slightly warm while riding. I replaced the plug, with a different style, no change. Still the occasional cut-out.
3. I then suspected the wiring at the head tube may have flexed one too many times and that my plugging and unplugging moved a broken wire back into place. The loss of power was fairly uncommon in the last two weeks, but the number of failures was increasing. So I replaced all motor power wires from the controller to the motor (I didn’t open the motor, just cut the wires close to the motor) with 10 gauge stranded wire. I noticed an increase in torque and the problem went away for over a week.
4. 2 weeks ago Friday on my ride to work, the power failed again. Totally dead this time no power to the wheels, all LED's working as they should. I could not restart the system. I had to call Phoenix EV rescue (my wife with the truck!!) Opened up the controller and found that the sensor less start board had become unstuck from the case. I built out a quick holder inside and buttoned the controller back up. All systems working fine for 1 week.
4. This Friday, totally dead again. All LED’s look fine.... I opened up the controller again and inspected every single wire and looked the entire board and sensor board over for blown parts. Tested all FET's with a meter. I found no issues, other then the main board is not well supported and appears to have the ability to flex, ever so slightly. The only thing holding the board in is the heat sink tabs on the FET's and some white foam weather strip type tape. I really really crappy way to install a board. So my though was that maybe one or more of the FET legs had failed due to vibration, like a paperclip if you bend it too much. I removed the rubber coating and tested all FET's. All are fine.
5. Since I didn’t replace the last 6 inches or so of wire at the hub motor, I suspected those wires now. A meter showed no issue, no matter how I moved or twisted the wires.
So here I am... I think that the controller has failed, either the sensor less board or the main board. Anyone have any other ideas?????????
or know where I can get a new controller (or used) cheap and quickly???????
bob in phx.
Symptoms before death.
1. Occasional loss of power. The power loss did not appear to be caused by bumps or turns or acceleration. I would be riding along and the power would just quit. Full throttle, part throttle, no pattern.
2. I was able to restart the system by unplugging the three wire motor connection. I did not have to turn off the controller or unplug the battery. I figured it was that controller to motor connection that was failing. Since new, the three wire trailer type plug has been a concern as it gets slightly warm while riding. I replaced the plug, with a different style, no change. Still the occasional cut-out.
3. I then suspected the wiring at the head tube may have flexed one too many times and that my plugging and unplugging moved a broken wire back into place. The loss of power was fairly uncommon in the last two weeks, but the number of failures was increasing. So I replaced all motor power wires from the controller to the motor (I didn’t open the motor, just cut the wires close to the motor) with 10 gauge stranded wire. I noticed an increase in torque and the problem went away for over a week.
4. 2 weeks ago Friday on my ride to work, the power failed again. Totally dead this time no power to the wheels, all LED's working as they should. I could not restart the system. I had to call Phoenix EV rescue (my wife with the truck!!) Opened up the controller and found that the sensor less start board had become unstuck from the case. I built out a quick holder inside and buttoned the controller back up. All systems working fine for 1 week.
4. This Friday, totally dead again. All LED’s look fine.... I opened up the controller again and inspected every single wire and looked the entire board and sensor board over for blown parts. Tested all FET's with a meter. I found no issues, other then the main board is not well supported and appears to have the ability to flex, ever so slightly. The only thing holding the board in is the heat sink tabs on the FET's and some white foam weather strip type tape. I really really crappy way to install a board. So my though was that maybe one or more of the FET legs had failed due to vibration, like a paperclip if you bend it too much. I removed the rubber coating and tested all FET's. All are fine.
5. Since I didn’t replace the last 6 inches or so of wire at the hub motor, I suspected those wires now. A meter showed no issue, no matter how I moved or twisted the wires.
So here I am... I think that the controller has failed, either the sensor less board or the main board. Anyone have any other ideas?????????
or know where I can get a new controller (or used) cheap and quickly???????
bob in phx.
