Amigafan2003 new build mk 2

[amigafan2003]

Ok, since retiring the commuter isn't getting much use so it's getting the MAC kit stripped off it and returned to stock. So time to have some fun with my next build:-

BBS02 48v500w crank drive kit.

Host bike.

Going to re-use the lipos as a 15s3p 12ah (63v hot) pack. Trying to decide between custom frame enclosure or saddle back.

Stay tuned for the build starting next week!

 

[trex]

are you sure the BBS02 can take 63V?

 

[amigafan2003]

are you sure the BBS02 can take 63V?

Yes. They have 63v caps and 75v mosfets.

I only charge my lipo to 4.15v per cell or 62.25v in total anyway as a safety buffer and to extend the packs life.

 

[Deleted member 4366]

Don't forget that over-volting will make the crank spin faster.

 

[trex]

My BBS01 spins about 80-85 RPM, I can't imagine what it's like running at 63V.

 

[Deleted member 4366]

My BBS01 spins about 80-85 RPM, I can't imagine what it's like running at 63V.

Perfect for Shanaze Reade

 

[amigafan2003]

It'll spin 15% faster, so 92rpm vs 80 rpm, still within my comfort zone - I'm ok with anything up to 100rpm..

 

[aardvark5]

Subscribed to thread (Dimple)

 

[amigafan2003]

Subscribed to thread (Dimple)

Hi Dimple

 

[Tangsoo]

Can I ask how do you get those cells into 15s3p and 63v? Also, how do you charge multi packs - still as one? But wouldn't that mess up the cell balance?

Edit - doh! I notice they're 5 cell.. not 2s as I thought.

 

[amigafan2003]

Can I ask how do you get those cells into 15s3p and 63v? Also, how do you charge multi packs - still as one? But wouldn't that mess up the cell balance?

Edit - doh! I notice they're 5 cell.. not 2s as I thought.

Yeah, you parallel three packs, then another three, then the last three and finally you series those parallel groups together:-

I bulk charge via a modified Meanwell power supply. As for balancing - I've never had to rebalance since the initial balance charge - that's around 200 cycles in 18 months. I just don't discharge the pack enough (never below 3.4v under load) where it imbalance becomes an issue.

Had a think about the battery - 15s3p is just a touch big to squeeze in the frame, so what I'm going to do is put a 15s2p pack in this and mount it to the bottle bosses and top shock mount. Then if I fancy a bit more range I can put the 15s1p pack in this - currently making the harness now.

The kit is fitted (bar the brake switches) and tests ok - photos soon!

 

[Tangsoo]

I've just taken delivery of [URL='http://www.amazon.co.uk/M-Wave-Amsterdam-Box-Cargo-Topcase/dp/B001EVAYFK/ref=sr_1_1?ie=UTF8&qid=1393060279&sr=8-1&keywords=bike+top+box']this. Really nice fit and as it's 100% waterproof it should be pretty handy, fed up of the rucksack so don't want to completely fill it with cells.

Needs a rack to fit it to but my 36v 10Ah slots into the carrier. Going to put my booster pack into it. should be nice & simple as it's a single pack.

Got a Graupner Ultramat 16s charger off eBay for when I get more adventurous.[/URL]

 

[aardvark5]

How far is your daily commute?

 

[amigafan2003]

Zero - I retired in July

 

[amigafan2003]

Progress update:-

Just finishing the battery box atm (the metal box I ordered was 1.6kg so decided not to use it!). The box can house 15s2p of lipo and the seat bag can do another 15s1p (can squeeze 15s2p in it but I think it's be a bit heavy for the bag). so 15s3p in total on the bike - 666wh in total.

Couple of observations - chainline isn't great so I had to refit the front deralieur and set the stops to stop the chain falling the front rings when on the largest gear at the rear. I have a DH chainguide coming to replace the dérailleur.

Taking it for a test ride later!

 

[103Alex1]

Just finishing the battery box atm (the metal box I ordered was 1.6kg so decided not to use it!).

Back to wood in the end ?

 

[amigafan2003]

Back to wood in the end ?

Yeah but I might cover it in cf

 

[103Alex1]

There's a lot to be said for it as a material - and you can use it to help keep warm when you're finished with it, too !

Yeah but I might cover it in cf

Who'll ever be any the wiser as to what's underneath . All looking good.

 

[amigafan2003]

As I'm using lipo @ 63v the controller LVC wont kick into protect the batteries and I'm not using a BMS (Battery Murdering System) so I need someway of keeping an eye on the voltages. As well as a cellog see below for my solution:-

0-100v two wires voltage meter fitted into a potting enclosure. Peice of right angled carbon fibre riveted to enclosure.

Mounted to one of the display screws.

Success! Cable is twin core spliced into the motor battery connector and fused with a 2a micro car fuse.

 

[amigafan2003]

Done:-

Still thinking of a more elegant solution for the frame mounted battery box.

I like Kepler's plan from ES:-