NOTE: Our 48V BBS02 controllers are fitted with IRFB3077 mosfets and have been since June 2015. It is still early days, but this upgrade does seem to have improved the reliability significantly. This product is sold without warranty as we have no way to confirm if the rest of your motor has issues that may damage the controller and as this is likely being bought to fix a bad kit, that is a quite likely scenario. Please note that the controller in the BBS02 kit, is NOT the only thing that can fail in the BBS02 kit, although it is typically the most common point of failure. Please be aware, if a good controller is connected to a motor that has previously been overheated or has some sort of issue, it will cause the controller to malfunction and likely fail in a short time. It is strongly recommended that the motor windings are also inspected for signs of damage if your BBS02 kit develops an issue. Do not assume the existing issue is only a controller issue.
This is the original version of the BBS02 controller. This was fitted to the BBS02 up to around April 2016. Anything prior to April 2016 will be this older version. Please see additional images for details of the case. The later version controller is slimmer and includes a seal to improve waterproofing.
If after fitting a new controller, the kit does not work as normal, stop and do some further checks. Please do not assume that we supplied a faulty controller because after you connected it, it made some funny noises, or didn’t perform normally. It is suggested that you at least do a visual inspection of the motor structure (opposite side of housing to the controller), looking for signs of overheating. A replacement controller will not fix burnt out motor windings!
This a replacement controller intended for the 48V 500W or 750W Bafang BBS02. As can be seen in the images, the controller includes a section of the motor housing and all connections. It may be necessary to change the battery supply connections, it does not come with the moulded waterproof supply connection, we fit 4mm bullet as standard. The sealed PCB makes these controllers rather difficult to do a DIY repair, so it is much more practical to simply swap the complete controller section.
The standard settings are as follows:
- 25A or 18A rated.
- LVC (low voltage cut) 41V, suitable for 47/48V battery. 43V LVC for 50V Battery.
- Will be configured so the throttle gives 100% assist no matter which assist level is selected.
- Number of assist levels are adjustable by the display.
- Wheel size can be adjusted from the display.
- Speed limit can be set via the display.
Controller Swap Procedure (hit the link)
Bafang BBS02 Mid Drive Kit Manual (hit the link)