diy
the ebike controller is an essential component used in electric bikes. without a controller or driver, bldc motors are not possible to run.
if suddenly the controller stopped working then how to know what are the problems in the controller? is there any procedure or method to check, does the controller need repairing or replacing?in this article, you will learn by using some basic methods about how to check, the ebike controller is working or not.
the list of components require
step 1: connect the battery with the controller.
first, connect the battery (I’m using an external power supply) with the controller as well as the activation wire present in the controller.
what is the function of activation or key switch wire:
it is used to activate the functions of other wires.depending upon the type of the controller its color may differ for different drivers.
step 2: set multimeter reading
set multimeter reading on 200VDC. with the help of a multimeter, check the voltage across the controller’s negative and positive wires.
it should be close to the battery supply.
every driver has the same number/color of a group of hall sensor wire.
now connect the negative wire(black wire) of the controller with black wire of multimeter (grounded) and another terminal to the positive supply of hall sensor wire.
it will show voltage around 4.9-5VDC.
if not then internally, the controller has a hall voltage issue. now follow the same to other color wire check the voltages at yellow, blue, and green it should be between 4.5-5VDC.
if you didn’t get any reading from above, it means that some functions are not working and the controller needs to be replaced or repair.
also, check if the motor hall sensors are working or not!
step 4: check the controller MOSFETs
set multimeter reading on diode/buzzer/continuity.
now connect a positive terminal of the multimeter with the negative wire and another terminal with phase wires (green, yellow, blue) of the controller.
check each phase wire of the controller. it must have to show some ohmic resistance range from 415-490ohm.
which is depends on the type of controller.
if it doesn’t show you ohmic resistance that means one of the MOSFETs is damaged internally and needs a replacement.
so this is the way you can find whether the controller is working or not. you can apply this method to any type of controller.
Electric Bike Maintenance Cost (Explained)
Electric bikes offer many advantages, including environmental friendliness, high speed, and fewer parking challenges at a low upfront cost. However, apart from the comparatively low initial purchase price as compared to a car, most people would love to know whether the running costs of e-bikes are affordable.
Electric bike maintenance costs include battery charging, battery replacement, motor repair and replacement, controller maintenance, and mechanical costs. The maintenance costs vary greatly depending on location, mileage, the type of e-bike, and how you ride your bicycle.
- Tune-up: 75-200
- Flat tire repair: 10-20
- New tire tube: 5-9
- Drivetrain adjustment: 20-60
- Brake pads and maintenance: 40-80 per set
Additionally, there are several unforeseen costs of replacing or repairing major components such as the battery, motor, sensors, or controller.
Thus, in the rest of the article, I’ll explain in detail the different maintenance costs of e-bikes. And I’ll also give you some valuable tips for lowering these costs.
Breakdown of E-Bike Maintenance Costs
There’s no one set cost of maintaining electric bikes since everyone uses them differently… and each electric bicycle is different. However, there are particular upkeep and maintenance practices that every e-bike owner has to consider when calculating a regular maintenance budget.
So, let’s take a close look at the regular maintenance and upkeep costs necessary for every electric bike owner:
Battery Charging Costs
Battery charging costs vary greatly depending on the electricity cost per kWh (kilowatt hours) in your location and your e-bike’s power needs.
- (kWh) x (the decimal value of the battery charging efficiency) x (the cost of your electricity per hour)
So, let’s look at an example using the average values for these figures. On average, an e-bike’s charging efficiency is at 95%, the average cost of electricity per kWh is 10.42 cents, and your e-bike battery rating is 1kWh.
Also, assuming you would like to ride for one hour, the average charging cost will be 1kWh0.9510.42cents =
Valuable Tips To Lower Your Electric Bike’s Maintenance Costs
So, now that you know the cost of keeping up with electric bikes, you might be wondering how you can keep maintenance costs minimal. You can do several things to keep your bike running in peak condition for longer.
Let’s look at some ways you can maintain your e-bike more efficiently:
- Charge your battery correctly. Since electric bike batteries are costly, you could reduce the maintenance costs by following the recommended best practices of use, such as not leaving the bike idle for long periods with the battery at 100%. I highly recommend charging until the battery is at 80% before using it and storing it at a charge less than 80%.
- Clean and lube your chain at home. Learning how to properly clean your e-bike and lube the chain will go a long way in reducing maintenance costs. Cleaning and lubing will make the chain and sprocket more durable and enhance the bicycle’s performance and reliability. It is advisable to clean and lube after every 200 miles.
- Replace cassettes yourself. You could also learn how to replace cassettes on YouTube. The tools cost 5000, and the cassette costs around 25. On average, you may only need to work for 20 minutes to finish the cassette repairs, but it saves you a lot of money. Find out whether you need a new cassette or freewheel on your electric bike.
- Get a hardened chain. I also recommend going for hardened chains when replacing your chain. Even though they cost more, they last longer and make the sprockets last longer because a damaged chain contributes immensely to the speed of the sprocket getting damaged.
- Use high-quality, durable tires. Getting puncture-proof bicycle tires will go a long way in helping you save a lot of money that you would have spent on replacing punctured tires. I recommend the Kenda brand tires (Amazon) as they’re generally highly rated for electric road bikes, hybrids, or city commuter electric bikes. It’s puncture-resistant, foldable, and manufactured using a high-quality nylon and rubber compound.
- Splurge on brakes. Don’t hesitate to spend a bit more on good brake pads and parts because e-bikes are very heavy and fast, and buying lower-end ones would mean very frequent replacements. Hydraulic disc brakes are a great option.
.10. So, that means that it will cost you about 10 cents for every hour you charge the battery. The charging price will vary from the
Final Thoughts
However, the electrical maintenance cost is not the same for everyone and greatly depends on the mileage, location, usage method, and e-bike type of specific riders.
Since both the electric and mechanical maintenance cost of electric bicycles can be very high, it’s advisable to follow a few tips to decrease it, such as making minor repairs at home and keeping up with good maintenance practices.
.10 average but usually not by much.
Generally, the 1kWh power consumption can power electric bikes for about 62 miles (~100km). Therefore, we can also represent the cost as 10 cents per 62 miles or 100km. The battery and motor are some of the most important mechanical components of electric bikes.
Battery Replacement Costs
Like all other batteries, your electric bike batteries will degrade over time and experience more significant voltage drops and less range on one charge.
The best electric bike companies use lithium-ion batteries during manufacture. Therefore, the number of charge cycles they can undergo before they need replacement is the same as that of lithium batteries.
E-bike battery life is typically a minimum of 500 charge cycles. Still, most of the time, you can stretch the charging cycles to 1000 on a lithium battery before battery wear is so severe that it urgently needs replacement. How long it lasts is also dependent upon how often you charge your e-bike battery.
A new battery for electric bikes ranges from 500 to 900 for a 500 Wh battery pack, though smaller batteries will be cheaper. You will need to replace your battery every 2 to 4 years, depending on how much you use it and how many charge cycles it undergoes during the time. Make sure you swap it out with an interchangeable battery.
When it’s close to its end of life (EOL), you may want to get a new second battery and start taking it with you as a backup. That way, you won’t get stuck far from home without any charge. A digital controller display will cost more to repair or replace
Tune-Up
It is always best for new electric bike owners to take their e-bikes to a professional mechanic for tuning before using them to ensure that everything is working correctly. You should also take your bike for routine maintenance after your first 500 miles (804 km).
However, tuning up is not a practice that is limited to new electric bicycles since it is advisable to take your electric bike for a tune-up once a year if you take regular weekend rides and twice a year if you ride it daily.
A tune-up involves checking and making adjustments on the drivetrain, brakes, the bearing system, and available bolts.
Most tune-ups also involve cleaning the cables and checking the electrical connections to ensure that they work correctly. The range from 75 to 200, with most companies offering different introductory and complete offers.
Regular servicing will help prevent accidents and severe damage since a professional can note any problems early and correct them.
Chains and Gears Replacement
Electric bikes’ chains and gears experience more wear because the electric motor and pedal assist can add extra wear and tear. The high speed of e-bikes and the great distances that most people ride using electric bikes also highly contribute to the wear.
You will need to regularly clean and lubricate the chain with dry or wet lube, depending on your riding conditions. Because I live in a dry climate with little rain, I use the Muc-Off dry lube from Amazon.
You may also need to replace the chain every 800 to 1000 miles (1,287 to 1,609 km). An bike chain can cost between 15 and 60. You also need to replace your cassettes after every 2796.17 miles (4,499 km).
How do I Reset my EBike Controller? Solved (with Pictures)
Electric Bike Controller is the brain of your e-bike, it controls every part of your e-bike starting from the battery, the motor, and throttle. As you have searched for the best way to reset your controller you may have an issue with your Ebike. I have published a post for the step by step troubleshooting guide you can check it from HERE As a general Rule C5 C10 parameters in your Ebike setting is responsible for resetting your controller. It should be set to 1Y to reset your electric bike controller to the default settings. Disclaimer: some controllers have different default values so it’s better to check your manufacturing manual before changing these values. Check Out this Amazing Ebike Controller, I love it, I think this is the best option for you if you decide to change your ebike ( Get it On Amazon From Here )
Step By Step guide to reset your E-bike controller.
1- To Go to your Ebike control panel, you need to turn your battery ON then Hold the function button for three seconds.
3-you will find your current setting appears on the screen and it will be blinking use the function button in the middle to cycle all the settings then hold again the up down button to enter the parameter settings
4-Once you see the P1 Value you should use the function button to cycle all the P Values (I will explain them later in this post Stay Tuned!) when it stops blinking then you should hold the up down button again to move to the C values.
7- to Save the value press hold the Function Button for three seconds once it is saved it will take you back to the main screen and you are good to go. 8- To reset the whole functions of the controller navigate to the C10 parameter choose Y to reset to the factory settings. (see the difference between the two parameters below)
Electric Bike Parameter settings meaning
I don’t know if you knew this information or not, but all electrical bikes in the United States are not manufactured in the United States! Yes, I watched some videos on YouTube talking about this information. I was just as shocked when I confirmed that all the brands and models sold in the United States are a collection of Chinese components assembled at the request of American companies. I’m mentioning this information because it will help us here in explaining the parameters of the electric bike control panel. Simply all the parameters have almost the same meaning if we take into account that the manufacturer for these parts is one place or country. Now let explain your E-Bike letters numbers. To log in to your parameters screen check the above step (from 1 to 3 )
P parameters
P1: This value means motor characteristics parameters which include info about voltage, frequency how your motor will perform with every value. Recommended not to mess around with this value unless you know what you are doing. P2: This means the control for your Speed sensor if you doubt that you have an issue with the speed sensor so better to check the default value in your manual. P3: this parameter controls your PAS or Pedal Assist functions usually it has values from 0 to 5 Zero means that you will depend on the PAS system completely Five Means that you will depend on the throttle power completely P4: Control the throttle startup and it has two values 0 Or 1 Zero Means that the throttle will activate the motor when it is triggered. One: This means that the throttle will not activate the motor unless you pedaling first. P5: This means how your controller will monitor your motor battery recommended not to mess around with these settings because if this value wasn’t set correctly you won’t be able to get correct info about your battery charging levels. (by default it will be set to 0 this value will show the real-time voltage mode).
Now let’s move to the C parameters
C1: setting for the throttle starting up Settings you need to check your manufacturing manual to set your preferred manual settings C2: is your motor classification code which is usually used if you have a scene wave drive motor C3: Controls the power assist ratio gear usually have values from 0 to 5 Zero: Almost no Pedal assist from the motor Five: the Highest Pedal Assist from the motor C4: This parameter is used to set your e-bike handlebar C5: This parameter is responsible for the maximum operating current as we mentioned you can use this to reset your controller. please make sure to check your e-bike manual before changing any value. C6: this parameter controls the backlit light LCD display usually is have five values from 1 to 5 one is the low brightness 5 is the highest. C7: cruise function settings (if your control has cruise function) 1 for ON zero to switch it OFF C8: this parameter will show the motor temperature settings C9: setting for setting up a password for your function panel C10: The factory reset settings (this with the reset the whole settings to the factory reset) if you want to reset all the settings all you need to do is to choose Y and Save it. C11: used for LCD attribute setting usually is have values from 0 to 2 C12: this will set the minimum operating voltage (better to leave this option as it is ) C13: This parameter controls your ABS Brakes settings C14: Is the power Assist tuning setting you can choose either 3 which is the highest or 1 is the lowest
Conclusion.
As a general rule, you can reset ebike controller by turning your ebike on then holding the up down buttons for three seconds then using the power button to go to the C parameter setting and set C5 to 1. The difference between the two parameters is that C10 is responsible for resetting all the characteristics of the controller. While parameter C5 is responsible for resetting the operational functions in the controller.
Troubleshooting Common Electric Bike Problems (Definitive Guide)
An electric bicycle is a reliable way of getting around, whether you need to get to work or want to explore the great outdoors on two wheels. However, just like a regular bicycle, an e-bike needs occasional maintenance and repairs.
The good news? You can check and fix many common e-bike problems on your own. This electric bike troubleshooting guide has you covered. Read on to learn about the most common electric bike issues and general tips for checking your e-bike’s functionality.
Common e-bike problems and how to fix them
Some common problems happen in e-bikes regardless of the brand, type, or model. Here are some issues you may experience as an e-bike owner, with a quick DIY troubleshooting guide, so you know how to address each one.
E-bike controller not working
Your e-bike controller connects the bike’s various electrical components, like the motor, throttle, pedal assist, battery, sensors, and LCD (if it has one). It’s basically like a small computer and coordinates the bike’s overall function.
Think about it like the brain of your e-bike. If it isn’t working, the e-bike’s brain isn’t working.
Various issues can impact the controller, like faulty wiring and other connections coming loose, the on/off switch not working, or the controller’s fuse or circuit breaker not functioning properly.
Take these steps to see if the e-bike controller is the issue:
- If the controller isn’t working, start by checking the power switch. Switch it on if it’s not in the “on” position.
- Check for any incorrectly connected, disconnected, or loose wiring. If you see improperly connected wires, you can reconnect them yourself. Most bike wiring is color-coded (so a blue wire matches a blue port or outlet).
- If the controller has a circuit breaker, reset the breaker. You can do this by pushing on it. Be aware that the circuit breaker is meant to protect the system, so if it keeps switching out, there might be a bigger problem requiring the entire system’s replacement.
- If the e-bike has a fuse, check to make sure it’s not burned out. You can remove the fuse and hold it to the light. You should be able to see if it’s burned out. If it is, you’ll need to replace it.
E-bike throttle not working
Some e-bikes have throttle assist and a pedal assist system (PAS). Throttle assist engages the motor even when you aren’t pedaling, powering the bike forward independently.
The throttle is what activates this mechanism. If there’s something wrong with the throttle, the throttle assist function won’t work.
In most cases, the throttle malfunctions because it’s been overused. If you push on the throttle for too long, it can get stuck in position and fail to revert. As a result, the throttle can become damaged or loose over time. You may notice that throttle assist simply cuts out while cycling.
Follow these steps to troubleshoot the throttle:
- Check the throttle’s position (by the bike’s handlebars). A malfunctioning throttle will generally get stuck in the rearmost position instead of popping back into place.
- Manually pull the throttle back into place. Under power failure, test the throttle by pushing it into the rearmost position and seeing if it pops back into place right away or lags.
- If the throttle doesn’t pop back into place or does so slowly, you’ll need to replace it.
E-bike pedal assist not working
The PAS helps power the bike forward while you’re pedaling. Most bikes have different levels of pedal assist, providing different levels of support.
For example, Velotric’s Nomad 1 and Discover 1 have five levels of pedal assist. If the pedal assist system isn’t working, you’ve basically got a regular bike.
The PAS may malfunction because of power cutoffs or inconsistencies in the power supply. Depending on the type of system, connectivity issues with the bike’s pedal, sprockets, chain paddles, or wheels might be to blame for the intermittent power. An issue with the magnet ring and sensor on the front sprocket can also be the cause.
Here’s how to figure out what’s causing your PAS problems:
- Check for any loose parts or connections if you’ve recently adjusted the mechanical components on your bike, like the sprockets or chain paddles.
- Look at the magnet ring on the bike’s front sprocket. It should be placed so that the magnet and sensor are aligned.
- If the magnet ring has been jostled out of place or is dirty, it might need adjusting. You can adjust the magnet using a flathead screwdriver, applying gentle pressure to move it closer to the sensor.
- If the above steps don’t work, you should visit a bike shop for professional help. They can identify, remove, and replace faulty parts.
E-bike battery not charging
If the e-bike controller is comparable to the vehicle’s brain, you could say the battery is like the e-bike’s heart. It keeps the bike’s motor going, allowing the PAS and throttle assist to work.
If the battery isn’t charging, you won’t be able to use your bike’s full functionality. The bike may not start or keep powering off, for example.
The e-bike battery can fail to charge for various reasons. A fuse might be blown, the battery might be depleted from too-frequent charging, or the battery pack may simply be old or defective.
Other e-bike tips
The more you know about your e-bike, the better you can care for it — and the longer it will last. Check your e-bike functionality using the below steps.
How to check e-bike battery voltage
The e-bike’s battery voltage determines its power. If the battery isn’t meeting its full voltage capacity, it might be old and need replacing — or, if you’re dealing with a new e-bike, the battery might be defective.
It’s good to identify defects immediately while your bike is still under warranty.
You can check an e-bike battery’s voltage with the help of a voltmeter or multimeter. Start by attaching the prongs of the device to the battery, aligning the positive and negative sides accordingly.
Alternatively, you can secure the voltmeter to the battery’s charger connector.
The voltmeter will show you if the battery drains faster than it should. If it drains too fast, determine when the battery was last charged.
If the battery pack hasn’t been charged for six months or less, it may need a top-up. If the battery pack hasn’t been charged in over six months, it might be defective.
How to test the e-bike battery charger
Sometimes, it’s not the battery that’s the issue but the battery charger. This is an easy issue to troubleshoot.
You don’t even need any tools to get it done. Plug the battery charger into an electric outlet. Ideally, the indicator light will come on and stay on steadily.
However, if there is an issue, the indicator light may not come on or blink intermittently. This indicates the charger isn’t getting power from the socket as it should.
You can use a voltmeter to double-check. The voltmeter should give a reading a little bit higher than the designated voltage of the charger. If the charger’s reading is below voltage, you’ll need to replace the charger.
How to diagnose e-bike wiring issues
The various components of your e-bike — like the controller, motor, and battery — are connected with wiring systems. These wires transfer power between these key parts, so if they’re loose, frayed, disconnected, or otherwise faulty, the e-bike might experience mechanical issues.
Consult your e-bike user manual to identify and locate the various wiring systems. For example, the e-bike controller (the “brain” of the bike) is one wired component.
Check for loose or incorrectly placed wires. This is simply because the wires are color-coded: A blue wire fits a blue port, a red wire fits a red port, and so on.
In some cases, loose wiring might be the issue. In others, the wire might be damaged. You can use a voltage tester to check a wire’s integrity, moving it along the length of the wire to determine where voltage is diminished — an indication of damage.
Depending on the issue, you might need to replace the wire. This is a job best left to a professional repair shop. They’ll know what parts to replace and can make sure they’re properly installed.
Experience the quality and reliability of a Velotric e-bike
You can help keep your e-bike in good working order — and hopefully avoid some of the issues described above — with regular maintenance. Our e-bike maintenance checklist covers some of the most important maintenance tasks.
Even with proper maintenance, every e-bike is bound to experience technical issues at some point. Knowing how to handle problems as they happen can make your life as an e-bike owner easier.
Investing in a good quality e-bike can help minimize the risk of needless problems. Velotric has tried-and-tested electric bicycles to suit every need.
Velotric’s Discover 1 bike has a 500/900 W rated/peak rear hub motor and a range of up to 65 miles. The 48V 14.4Ah battery is certified by Underwriters Laboratories (UL2271), a global safety standards organization, and charges fully in just six hours.
For a more rugged ride, try the Nomad 1 bike. It has fat front and rear wheels, giving you greater stability on unpaved surfaces. The Nomad 1 has a 750/1,200 W rated/peak motor and a range of up to 55 miles (slightly less because the bike is heavier).
For either bike, you can choose a frame that fits your size and needs. The high-step model is best for cyclists 5’6” to 6’9”, while the step-through model fits cyclists 5’1” to 6’4”. Learn more about the different types of bike frames.
Whichever bike you choose, you can be sure you’re getting a quality product. Our bike frames have been rigorously tested more than 150,000 times, ensuring your safety and comfort.