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Unread 04-12-2017, 06:03 PM   #1
Not Yet Wild
 
Join Date: Apr 2017
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Default How do you test a BBB Sevcon controller?

I bought this 09 BBB "stretch" w/4wd, 2 motors 48volt. Long story short, I have only the rear wheels pulling. I have one controller (sevcon) with a solid green light and one not lit at all. At the solenoids I get 48v from the small red and green wires on one, and 26v from the other. My question is, how do I test the controller to make sure that it is the problem? I already replaced one solenoid unnecessarily, and what are my alternatives if its the controller?
I'm including some photos if that will help. RR
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Unread 07-06-2018, 07:56 PM   #2
Not Yet Wild
 
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Smile Re: How do you test a BBB Sevcon controller?

Did you ever get any response? Im at same point in a rebuild
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Unread 07-10-2018, 07:08 AM   #3
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Default Re: How do you test a BBB Sevcon controller?

There is a little red LED one corner of these controllers, and while you can find no help from BBB themselves (you know it's bad when even hunting forums despise these carts) you can download the PDF file for the Sevcon Millipak manual. They should power up, LED lights once, and if there's any codes stored, they will flash a number of times, pause, and repeat until power is cycled.

One not lighting up at all is obviously not getting power or got fried somehow. Usually on these carts you'll get a 3 flash meaning MOSFET Short Circuit.

To power up the controller manually (thus eliminating a wire harness problem) download the manual and it should show the pins necessary for power input. You'll have to jumper in some wires to test or at least measure with a multimeter to determine if a wire is broken. Sometimes you can just jump pack voltage to B+ and B- as some of these cars (Lord knows they change everything all the time!) get controller input from the solenoid 'nest' under the seat.

These controllers normally don't open circuit where no LED flashes a code. I bet one of the two solenoids in the 'nest' isn't powering on or completing the circuit to the one controller.
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