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Controller Failure and Malfunction
Controllers
can fail for several reasons, the most common are moisture, overload,
shock and modification .
The main reason controllers fail
is moisture . Most controllers are ventilated for heat dispersion ,
unfortunently this ventilation is an open invitation to water through
condensation or direct contact . Several scooter manufactures place the
controller in the battery pan, this is an example of terribly negligent
design because moisture is bound contact the controller.
Overload
occurs when to much current passes through the system resulting in
heat damage. This problem is usually due to poor electrical design and
or controller construction. Electrical design problems can be extremely
simple to diagnose EX .use a smaller main fuse, replace bad motor or
very complicated, like hunting a ghost EX. EMF distortion issues. A
good controller will protect itself from overload, it may
refuse user commands but the controller will survive.
Scooters rarely use a common
ground design for safety and electrical noise minimization, but even
small distortions can cause controller malfunction or even damage. The
only way to keep these distortions to a minimum is by bundling (keep
the
wires together) so the emission from one wire is absorbed by another
and through controller centralization (placement of the controller in
the middle of the field) although this is actually impossible due to
the fact the
main EMF generating systems are the motor, and the controller itself.
So the perfect location for a controller would be on the motor but this
would cause a heat issue so keep the motor system and battery system
wires close together while keeping wires as short as possible and place
the controller in a location close to the motor and away from moisture
(good luck).
Shock damage is caused by the
user and occurs when the charger is plugged into the AC current before
it is plugged into the scooter's charging port causing the controller
to
recognize the charger several times while sending arcs of static and
blasts of DC current into the controller possibly causing controller
syntax jumping , when this occurs anything the controller is capable of
may happen and even result in
SCR damage causing the system to run at
full power when the charger is de-energized or removed .
Modification, these problems
actually fall in in the poor construction category . Custom
modifications can cause controller failure . Never use a ground other
than the battery ( no common frame grounding ), avoid emissions and
overloading any controller circuit . Never supercharge , don't pull
power from the lock circuit . Use proper size wires and fuse protection
. Don't bypass the charging or break (not break light ) circuit . Avoid
generation or reverse generation , this occurs when the motor turns at
high speed without power , rolling backwards at high speed or rolling
forward at high speed while not under power with freewheel malfunction
, the motor acts as a generator sending current back to the controller
.
Happy Scootering