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[Burton]

Yes I googled around. Found a "kit" for 900 which includes the USB to CANopen Bus here http://www.electricmotorsport.com/ev-parts/controllers/sevcon-gen4-36-48-280.html but it is $900 0_0

My encoder was acting up last week and I accidentally "fixed" it by backing the bike up after breaking down in the rain at 11pm on the highway.

Well it was raining again today even though it also rained yesterday and I broke down again -_- Only this time I couldn't reset it. I tried reversing to reset and I tried power cycling while moving at speed.

I was lucky enough to get the motor not to turn off so I could get home 4 miles away. The whole process took me 2 hours >_<

Anyway I was told I need to reset the encoder if not replace it. Both tasks will require DVT and if I am ever to make my own variable regen circuit I will also need DVT.

Suggestions more than welcome. The bike isn't dried off yet but when I start it the motor sounds like it is just about to move the rear wheel. I will likely have to ride my ICE bike till it is fixed >_<

[Burton]

Unsealed encoder ... -_- twice now in the rain I have broke down, now I know why.

Going to let the bike dry out and see if the encoder still works. Then seal it. Might not need DVT yet, but I will when I make my regen circuit.

[Doug S]

Burton, you might try flushing it with alcohol, hoping to get any contaminants out that the water may have deposited. I wouldn't try acetone; it leaves a white residue itself that I wouldn't trust...and besides, acetone can be hostile to some plastics.

[Burton]

I am just going to let it dry out naturally

Then put some dielectric grease in these and seal off any other holes

Thanks for the tip though. Would rubbing alcohol work or should it be 200 proof? Lol

[Justin Andrews]

I suspect the cut outs sections on your motor are not helping at all here either.

I can see an O ring water seal over the encoder, however where the sensor wires exit the encoders enclosure is not sealed either, probably because that hole is normally sealed inside the motor, and has been exposed when the motor was cut open. Water getting onto the windings can also cause the Sevcon to trip into a fault mode.

[Burton]

I suspect the cut outs sections on your motor are not helping at all here either.

I can see an O ring water seal over the encoder, however where the sensor wires exit the encoders enclosure is not sealed either, probably because that hole is normally sealed inside the motor, and has been exposed when the motor was cut open. Water getting onto the windings can also cause the Sevcon to trip into a fault mode.

Harlan pointed this out to me as well. Silicon is now sealing those holes The error I am getting is a encoder error, one where your motor doesn't know forward from backward. What happens when the windings get wet?

[Justin Andrews]

In my case the Sevcon would'nt fire up the contactor as it saw the wet windings as a voltage leak.

[Burton]

Ah, my bike  was already in motion at the time

Do you have a ventilated motor as well?

[Justin Andrews]

My old 2012 ZF9 did. My 2013 has a standard unaltered motor.

I think that you are right, and that because of the cutouts you are going to have to seal the encoder. Although I suspect if the encoder is optical (someone else here will surely know the answer to that question) you'll have to be careful not to obscure the optics...

I'd consider also looking at how the water is getting into the encoder as well, as could moisture build up on the encoder wheel also cause issues beyond electrical issues?

Again there are more experienced engineers on the forum that I however.

[Burton]

I will see if EC  knows if it is optical or not as I don't want to take it out till I get the DVT in hand. A forum member struck a deal with me so I should have a copy and dongle soon.

If it is optical sealing from the back is likely safe. But if the optic is exposed inside you might get issues, time will tell of course.

In my case there was one screw missing on the cover and the white wires going into the area are not sealed. I suspect this is how eater got in there.

[Doug S]

Thanks for the tip though. Would rubbing alcohol work or should it be 200 proof? Lol

Pretty much any clean alcohol would work; even if it has a little benzene in it (like rubbing alcohol) it should leave very little residue, certainly less than random water pickup would deposit. I'd think you could find a better use for 200 proof ethanol though!

I'm intrigued by the ventilated motor on your bike, which apparently isn't unique. I'd never do it on my bike because though I don't ride in the rain on purpose, it does happen and I'd never want to ride in the wet with an un-sealed motor. But I'm curious...I know the new motors are built with the magnets on the rotor and the coils on the stator so the coils can be cooled more easily. Were earlier years' motors constructed with the coils on the rotor, or is ventilating the motor just intended to get some cooling airflow on both sides of the coils?

[Burton]

Unless your planning to streamline your bike or race it ventilating the motor likely isn't worth the effort if your not overheating keeping in mind this bike has a size 6 controller with all limits removed.

EC informed me no motor ever made by zero need be sealed. He should know as he does race them. Terry wanted to vent his motor as well to avoid heat related issues. Since EC was racing the bike hard heat became an issue and he ventilated the motor to better compete; I assume.

I plan on making air ducts to get more cooling to the battery and motor post streamlining.

This motor also has a thousand dollars of ceramic bearings in it as well though I can't tell you if it makes a difference as I have no stock motor to test against. I am sure it does though or EC wouldn't have spent the money.

In the future if someone gives me a good deal on a stock motor and encoder I will certainly test it vis this heavily modified one. Need to get s cycle analyst installed first though.

[Burton]

Sealed off wholes with black silicon and put dielectric grease all over encoder and bay door