EHC replacement

Energy One
Axel

Axel

Active Member
Hi Todd,

Hm, this should not happen. Pls. send the EHC back to me for checking out. Do you have about 8 - 10 days time until I get the defect device or do you want me to send a new one asap? I would like to program the 3 flashes for the brake light in the new devices but need a few days if a small delay would be ok for you.

All the best!
Axel
 
Axel

Axel

Active Member
By the way, does somebody knows the maximum current or the dc resistance of the ignition coil? The maximum current to the ignition is about 12 Ampere.

Todd, pls. could you check if the red cable from A19 to the ignition module still have 12 Volt if the ignition is on (...if possible) ? Thanks a lot!

All the best!
Axel
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Axel said:
By the way, does somebody knows the maximum current or the dc resistance of the ignition coil? The maximum current to the ignition is about 12 Ampere.

Todd, pls. could you check if the red cable from A19 to the ignition module still have 12 Volt if the ignition is on (...if possible) ? Thanks a lot!

All the best!
Axel
Click to expand...
They are 3 ohm coils.


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Rottweiler

Rottweiler

Well-Known Member
Axel said:
By the way, does somebody knows the maximum current or the dc resistance of the ignition coil? The maximum current to the ignition is about 12 Ampere.

Todd, pls. could you check if the red cable from A19 to the ignition module still have 12 Volt if the ignition is on (...if possible) ? Thanks a lot!

All the best!
Axel
Click to expand...
Axel The ehc is already out of the bike. Yes I believe pin 13 and 14 where still hot? I had red light on thunder heart ignition module. Pins 16 and 17 where not? I will test my light tonight by putting 12 volts on 16 and 36 then 17 and 36. This is the 2004 model with just one 50 pin connector.
 
Axel

Axel

Active Member
Hi Todd,

Oops, I have open the wrong diagram before, I´m just be back from a small family tour and not back in my workshop with my head yet...
Yes, this would be great if you can check the pins. I attach a board drawing and have indicated the high side switches and their switching function. Where are the "heat bubbles" located on the potting material? Thanks!

Board.png
 
Rottweiler

Rottweiler

Well-Known Member
Hi Axel
Sorry about the delay. My bike is at my son's house and computer is at mine. The bubbles were between the ( 12V lg ) and the word ( Right )
The head light plug fell off the bulb. Not sure why it was a new bulb and porcelain plug I just put on this year. I bent the tabs on the bulb a little to help hold plug on? Would no load over heat it?
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Rottweiler said:
Hi Axel
Sorry about the delay. My bike is at my son's house and computer is at mine. The bubbles were between the ( 12V lg ) and the word ( Right )
The head light plug fell off the bulb. Not sure why it was a new bulb and porcelain plug I just put on this year. I bent the tabs on the bulb a little to help hold plug on? Would no load over heat it?
Click to expand...
Got a pic of the box?..

Not all those ceramic plugs are that great. I bought a couple different ones before I got a tight fit. You want to find the one that you swear it's too tight!

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Rottweiler

Rottweiler

Well-Known Member
Th3InfamousI said:
Got a pic of the box?..

Not all those ceramic plugs are that great. I bought a couple different ones before I got a tight fit. You want to find the one that you swear it's too tight!

Sent from my 831C using Tapatalk
Click to expand...
Yes I found out. I tried to push a small screw driver in to tighten up the plugs but thought it was going to break the ceramic? So I took a pair of needle nose pliers and twisted the stabs on the bulb. Had to push hard to plug it together. Hope that works. It would suck to have it fall off at night. Only rode it about 40 miles since head light was installed. Last ride was it day light bike was running great. Maybe I tested it too hard. :D:D
 
Last edited:
Rottweiler

Rottweiler

Well-Known Member
The box looks the same after it cooled down. Can't really see anything. I pulled the fuse soon after I hear the noise.
 
Axel

Axel

Active Member
Hm, a short circuit will drive the high side switches to about 150 degree Celsius until they switch off. The bubbes are between the high side switches in the middle of nowhere on the board. There is just a bit 5mm copper between the highside switches what should handle about 20 Ampere with about 100 degree temperature increase (see white circle):

Board.png

It is the main line from the 12 Volt to the other highside switches. The rest of the copper track have 6,5 mm width and is partly covered with the switches what have a lower temperature resistance. I fear, that the 5mm worked as "unwanted fuse" after a while with the short circuit :-(. The highside switch for the light can handle 12 Ampere per channel and will limit if higher currents are present. Are the other functions of the box working correct?

All the best!
Axel
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Axle,

How did you know it's there? Did he send you a picture?

If it's on the main line you don't really know what cause it could have been a few different areas?


BWG56 said:
I wonder what caused the short circuit? :oldconfused:
Click to expand...



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BWG56

BWG56

Guru
Rottweiler said:
Hi Axel
Sorry about the delay. My bike is at my son's house and computer is at mine. The bubbles were between the ( 12V lg ) and the word ( Right )
The head light plug fell off the bulb. Not sure why it was a new bulb and porcelain plug I just put on this year. I bent the tabs on the bulb a little to help hold plug on? Would no load over heat it?
Click to expand...
Th3InfamousI said:
Axle,

How did you know it's there? Did he send you a picture?
If it's on the main line you don't really know what cause it could have been a few different areas?
Sent from my 831C using Tapatalk
Click to expand...
Please read all replies :oldrant::oldbang: :oldhardlaugh::oldhardlaugh::boing:
 
Axel

Axel

Active Member
Hi Eric,

Yes, he told in post 501: "The bubbles were between the ( 12V lg ) and the word ( Right )" what was indicated in my preview post. It might be the position. There is just the copper at this position.

However the left high side switch is responsible for the head light and a short circuit might affect to the copper layer. Let´s see...

All the best!
Axel
 
Axel

Axel

Active Member
Hi Ker,

Yes, this need to be find out. A bigger copper layer will help the board to survive but not the harness if higher currents will be present. The high side switch will limit somewhere between 12 and 20 Ampere. Maybe an additional internal self reseteable fuse will help. For the headlight I use 2 channels parallel of the internal high side switch what will increase the current to 12 amp. Only one output be connected to the headlight will follow in an increase of the temperature in the switch what I don´t prefer. Every temperature change will reduce the life time of a part.

Let´s see...

All the best!
Axel
 
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