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Motor Drive Servicing

Your Galibier drive system was designed for years of trouble-free operation, but in the event of either servicing or performing an upgrade, the 5 minute procedure below shows how to prepare your controller module for shipping to Galibier.

  • We designed the drive system so you need only send us the module attached to the top plate.
  • The heavy motor pod should not be shipped to us.
  • Since 2003, the top plate separates from the motor plug by unplugging the power umbilical from the circuit board.

Please contact us for instructions on how to pack and ship your controller.  It’s important that you protect the motor shaft from damage !!!

While the motor is extremely robust in normal use, it is still a precision device, and it must be adequately protected from the rigors of shipping.  The standard “drop test” shippers perform to certify packaging is from a height of 6 feet.  This generates a force of over 40g’s (40 times the force of gravity).

Step-1:  Remove the Pulley

Click the thumbnail photos for expanded views.

  • You’ll need an .050″ hex key to remove the pulley.  Shown below are two varieties (“L” shaped and screwdriver handle).  Contact us if you can’t access one and we’ll mail one to you.
  • Controllers built since 2014 have either a black or silver pulley.  Pulleys in the second photo are shown upside down to reveal set screw holes.  The black pulley is fixed to the motor shaft with 4 set screws, and the silver one with 3.
  • Using your hex key of choice, loosen the set screws (1/2 turn will suffice), and lift the pulley up from the motor shaft:

Galibier Design - Motor Pulley Removal   Galibier Design - Motor Pulley Removal   Galibier Design - Motor Pulley Removal   Galibier Design - Motor Pulley Removal

Step-2:  Separate the Top Plate from the Motor Pod:

 

Galibier Design - Controller ServicingUsing a 5/64″ hex key, unscrew the 8 screws along the perimeter of the top plate and lift the top plate.

The pulley is still attached in this photo, although you will have already removed it.

 

Step-3: Unplug Power Cable

Galibier Design - Unplugging Power UmbilicalProduction Boards: Rev 1.02 (03/04/2014) and Rev 1.03 (07/14/2019)

Shown here is 2014 production board. You will see the revision number and date silk-screened on the board.  Scroll to the bottom of this page to view earlier versions (Rev 1.00 & 1.01).

Hold the top plate in one hand and unplug the power supply wires by pulling the plug horizontally (sideways), as shown by the arrow in the photo.

!!! Do NOT UNSCREW THE WIRES FROM THE PLUG !!!

You do not need to pinch or squeeze the plug in order to remove it.

The next photo on this page shows the plug assembly after it has been separated from the board.

The board shown in the photo is the 2014 revision after the 2018 update has been performed.

 

Finis!

YoGalibier Design - Controller Servicingur top plate/circuit board assembly is now separated from the motor pod and is ready for packing and shipping.

Pack it well (lots of bubble-wrap), box it up and ship it to us.

To re-install, reverse the steps 2 & 3 (we’ll have attached the pulley for you).

 

 

 

Beta Unit & Early Production Boards – Rev 1.00 & Rev 1.01

 Galibier Design - Controller ServicingBeta Units – Rev 1.00:

There are 10 of “beta” units in the field.  They have a single toggle switch on the top plate – no push switches.

Early Production – Rev 1.01: 

These early production boards have two push switches on the top plate (replacing the single toggle switch).  The top looks the same as Rev 1.02 and Rev 1.03.

 

 

Header block differences (the green plug):

  • Both 1.00 and 1.01 versions have “vertical” header blocks – the green, female section of the power plug.
  • Some early motor pods had shallower cavities, and we soldered them to the circuit board using “flying leads” (shown in the photo).  This provided vertical clearance for these shallow motor pod cavities.
  • The remaining boards resemble the production boards with the block soldered directly to the circuit board.

Unplugging the power wire:

1:  If  the green header block is connected to the circuit board via wires (“flying leads”) as shown in the photo, pull the two green  plug halves “apart”.

2:  If the green header block is soldered directly to the circuit board (no wires), unplug it by pulling the male part of the green plug upwards (away from the circuit board).