Electric Motorcycle Blows Up!!!!
 

:mad:
OK, well, no giant fireball, as there was no gasoline involved.

I was stopped at a three-way stop sign. When I went to pull away from the stop sign, it didn't go and a giant plume of smoke puffed up from under the seat.:mad::(

I hit all the power and disconnects and pushed it out of traffic.
I walked 2.5 miles home, stopping at the former Curtis controller guy's place.

He seemed to confirm that the problem was most likely the controller. I saw NO damage to the DC/DC converter or the main power contactor. I didn't see anything wrong with the motor, but it's hard to see anything without the cover off anyways.


Yep. I just walked in the door and the first thing I do is post a message about it! Haven't even had a glass of water left.:rolleyes:

Bummer!! Maybe related or not - but did you have a pre-charge resistor in the circuit?

Got warranty?

You let out the magic smoke. Everyone knows electronics don't work if you let the smoke out. ;)

On the serious side, maybe you just blew out an electrolitic capacitor. The plates can short, the electrolyte boils out, lots of smoke.
If that is all, it should be an easy fix.

Yes, I did. I believe the pre-charge resistor only effects the controller when turning the contactor on and off, which is only done manually at the start and end of a ride.


It sure was a lot of smoke.

Just got back with the cycle in the back of the S10. I lowered the back, but haven't had time to lower the front yet. Sure rides low with the blocks AND a cycle loaded in it!

Sorry to hear that Ben. Hopefully you'll have it sorted out soon.

Yep, it's the controller.

See the pix.

Notice the hole?
http://gallery.mac.com/benhdvideoguy...C06285/web.jpg


This is what it looks like from the other side.
http://gallery.mac.com/benhdvideoguy...C06288/web.jpg

The inside of the controller has epoxy filled in there so it's totally waterproof. When this thing went, it must have blasted a hole right through the end there!

That also means that you can't just get in and replace a single electronic part.
I am calling Alltrax customer service tommorow. Why do I have the feeling my one year warranty just expired.

See all the photos here:
http://gallery.mac.com/benhdvideoguy#100075

The inside of the controller has epoxy filled in there so it's totally waterproof.

Also it makes it that much harder to reverse-engineer/check-for-patent-violations.
There are epoxy removers that claim to be "safe" but I think the PC board has epoxy in it..
http://www.fiber-tensioners.com/BIO-SAFE1025specs.htm

Total bummer!

Actually, I did just dig up the original purchase date info.

Yep, if it was a one year warranty, it was up last week!

But was that date the order date, or the date it arrived and you had possesion? Because I would think the warranty would start when you got your hands on the part.

I'm an elect tech... And I thought I was the only one that said that!!!!

Ben - I wonder if it's a coincidence that this happened so shortly after you upgraded your pack voltage. I know it's rated for 48v, but what might the peak charging voltage be on your new charger? (Your controller probably isn't electrically connected when charging, is it?)

Wow. This is the first EV casualty I've ever herd of. Thanks for sharing, Ben N.

I wonder if by chance the batteries charged to a state that the controller couldn't
properly handle.

does Alltrax have a bad rep by any chance? soon i will be looking for which brand
controller to buy.

Another thought - do you still have the forklift's controller lying around or are you planning to use that with your metro?

Best of luck on repairs. :)

They might work with you on that, call and talk to them. Maybe they will give you a cost break on the next one.

Here's the voltage specs on the AXE from Alltrax's web page:

"Type: DC "SERIES WOUND" motor controller
Undervoltage cutback: adjustable, 16-30 VDC
Overvoltage shutdown: adjustable,
30-60 VDC (48V models) (60VDC MAX)"

The highest I have ever seen the battery pack voltage at was 55 volts.

The controller is disconnected from the pack while charging.

That's really a shame to see. Hopefully you get it all sorted out quickly so you don't have to burn too much more FF to get around!

It's worth calling them up, it never looks good on their part to have their product fail like this, even more so on a vehicle that is in public view.

Preliminary good news.. I looked up and found that the Alltrax has a TWO YEAR WARRANTY!

I got a call back from the warranty guy at Alltrax, saying that the best thing might be for me to contact the company I purchased the controller from, because I might be able to get a new one faster that way.

I am still waiting on a call back from my original dealer.

i hope this gets sorted out for you shortly, such a bummer that it happened though.

bummer it happened yes but if you get a replacement thats great ... it was flawed if it burnt up with in a year.

Got an e-mail from my dealer.

I am supposed to ship the original back to the manufacturer and the dealer will be shipping me a new one out tomorrow!

Yea, warranty coverage!!!!!

congrats:thumbup:

Nice!

happy that its working out for you :)

Bicycled to the post office today and mailed the Alltrax AXE back to the manufacturer.

Much quicker on the motorcycle than a bicycle....

Electric Motorcycle Blows Up!
 

Its very awesome Motorcycle. Thanks for sharing this one.

:turtle:

(Ben is currently on the road)

Last time I talked to my wife on the phone, she said the controller has shown up in the mail!

Yea!

I'm sure you've seen this; Modded electric motorcycle is street-legal, costs under $2K - Engadget

But regardless Congrats on the coverage :-)
Maybe the publicity can make up for the burnt controller? Ok, Maybe not . . . .

Motorcycle is back together and works great!

Went off-roading at the MREA energy fair....

That's good news bennelson.