Peugeot revisited...

[NRG]

Look what the DHL man brought me:

Prompt delivery from Frank, took just 5 days for delivery.

He's programmed the controller for 15Amps and I have the choice of 36v or going up to 48v so should be interesting. I bought both a twist throttle and thumb throttle. I like the idea of a thumb throttle on the left side of the handlebars with the 3 stage power switch on the right, like Daniel has on the Brompton.

The Bafang sure is lighter than the current installed Cohnis, so I can't wait to get started!

Not sure if I should lace the wheel my self or just let SJS do it....I'm tempted to have a go but don't want to mess it up....

 

[Herb]

I have the choice of 36v or going up to 48v so should be interesting.

That is interesting.

Have you bought a 48v controller programmed with a 36V low voltage cut off ?

I have only just fitted (today) a speedo to my 26” 36V bafang. I certainty get higher no load speeds when using higher voltage batteries – just a 3 or 4 volts will raise the speed by 4 MPH , but I would be worried about damaging the 36v controller if I go to 48V.

This looks a great scheme and I am quite envious of your project.

Herb

 

[NRG]

Good point Herb, I did ask Frank at the time but you've made me doubt what I asked for! I've just emailed him to confirm...I think I'm going to take your advise and get SJS to lace the wheel, they only want £40 to do it plus parts and I'm a bit pressed for spare time at the moment....

 

[eddieo]

Good move! SJS know what they are doing

 

[Herb]

He's programmed the controller for 15Amps and I have the choice of 36v or going up to 48v

NRG - your 36/48 volt controller has inspired my Fantasy Battery.

I already own two 6S A123 cell packs giving 39.6 volts.

Obtain an extra 3S A123 pack of cells = 9.3 volts.

Run off the 1st pack for normal riding and switch in the extra 9.3 volts for extra speed /power at 49 volts.

I am sure you are using a homemade Lippo pack and could carry out a similar mod to get the higher voltage ?

Herb

 

[NRG]

Yes, exactly Herb that was my thinking. I'm running 7s3p at the moment the 7s are made up a 4s and a 3s...I can reconfigure for 10s2p (37v) by using 4+3+3 ( I bought another 3s pack ), for higher voltage I have on order 3x 5s from Hobbycity so should be able to go to 12s or 15s...wiring might get a bit tricky though!

 

[Herb]

This is getting interesting – NRG is so formal - can I call you N

I think the control could be accomplished with a single two way switch, the common connected to the controller, one pole to the final positive (high volts) the other to a positive (low volts) two thirds along the series stack.
All the negatives connected together, not sure if we need diodes on this connection.

My problem is I am only working with 2.3aAh if I use the A123s. I really need to combine the 36V 10Ah Ping with extra batteries but I’m think there will be complications with the BMS.

Anyway this is only a Fantasy Battery - Less chat you must get on with your build.

Herb

 

[NRG]

Call me anything you want as long as its not insulting!

Frank has confirmed the controller is good for up to 56v max. So 48/36 should not be a problem...

Herb the only concerns I have with a dual voltage setup is the uneven draw from the two battery halves IE: the main halve if used more will run down quicker than the boost halve (maybe not a huge issue but worth keeping in mind) and possibly a problem when switching a high current inductive load.

I think protection diodes would be a wise idea....a make before break relay setup would work I think, switching in the positive side of the boost battery first and then a second relay disconnecting the positive feed from the fist halve immediately afterwards....

Anyhow, tested the motor yesterday, the low setting gave 120RPM or a calculated 10mph with 700C wheel, mid setting 170RPM / 14mph and high was 190RPM / 16mph... at 37V

 

[Herb]

Frank has confirmed the controller is good for up to 56v max.

I have just ordered a A123 2 cell pack from electricwingman this will bring the freshly charged voltage up to 50.4 (14 x3.6) and the nominal to 46.2 volts.

Initially I will just connect all the packs in series.

I believe I have the same controller (supplied by Frank) and will publish the speeds when I receive the cells.

I am not sure if I am realy after speed or power or just curious about the effects of the higher voltage.

Herb

 

[daniel.weck]

Frank has confirmed the controller is good for up to 56v max. So 48/36 should not be a problem...

Oooh, very interesting !

Could you please confirm that your controller board is a EB806 / XC-C-3 ? (you'd need to open the casing)

As far as I know, this is a small 6x MOSFET (P60NF06) controller designed by e-Crazyman (Keywin Ge), sometimes labeled as manufactured by Shenzhen Sucteam, and inside they look just like other low-power Infineon controllers.

See here for more info:

http://www.pedelecs.co.uk/forum/electric-bicycles/5100-can-i-get-more-power-my-36v-250w-bafang-10ah-battery-3.html#post64770

 

[Herb]

I also contacted Frank to ask if the controller he supplied for my road bike could take a higher voltage.

His reply

“ The maximum voltage, full loaded battery is 55v, for any higher you need another Controller. “

I also emailed E-Crazyman via Ebay, who I believe supplies Frank with controllers

His reply

“ Thanks for looking ,you can use this controller working at 54v but the LVC still is 31.5v. “

So I intend to start experimenting with 48 volts as soon as my extra A123 cells arrive.

Herb

 

[NRG]

Good one Herb. SJS have my motor and confirmed the wheel build so looking forward to getting it back.

Daniel, interesting link, I missed that one. My controller is different though, basic layout the same but different marking:

Board:

Its using the IRF3205 Mosfet, 55v VDss so there's the voltage limit. Current is 110A max but typical 75A...Mosfet caps are 50v rated so don't know what these 'see' accross them in operation...

My Celllog8's turned up today but I've made a mistake and will need another doh!

 

[daniel.weck]

Thank you NRG, that explains the voltage characteristics. ++Dan

 

[NRG]

My wheel arrived from SJS early this morning (pics to follow) the turn around was excellent. I shipped it Monday and it turned up today! First class job as well...13g spokes in a 2x lace pattern...it looks great. Great service from SJS.

 

[eddieo]

My wheel arrived from SJS early this morning (pics to follow) the turn around was excellent. I shipped it Monday and it turned up today! First class job as well...13g spokes in a 2x lace pattern...it looks great. Great service from SJS.

what was the cost?

 

[NRG]

£96 delivered, Ryhno wheel, spokes, the build and rim tape...no way could I have done it in such a short time. All up weight just under 4Kg no tyre.

 

[NRG]

Not much has happened on my re-build as I've had a paint brush stuck to my hand for the last two weekends. However, these arrived a few days ago:

from powerwerx.com in the USA, prompt shipping arrived in about a week. I couldn't find a UK supplier...maybe just didn't look hard enough. Anyhow I managed to build up my new wire loom for the battery, I think I'm going to have to reduce the number of connections a few too many and my CB is now overrated so I need a new one at 15Amps.

Also my new batteries arrived from Hobbyking, now I can experiment with different voltages and see how it affects performance.

 

[NRG]

Well, its finished (nearly!). Have to say it was an easy upgrade compared to the first build, maybe the parts are better or I know more now than I did back then!

The bike has managed to shed about 5Kg, would have been a touch more but I also replaced the front rigid forks with some suspension items, can't wait to try it out. The motor slotted into the front forks with no problems, plenty of clearance.

I stuck with the half twist throttle, would have liked to try the thumb throttle on the left but the front gear shifters made this a no go so the 3 speed/power level switch lives there instead. Speaking of which I ran the motor up and got the following speeds, 1=10.5mph, 2=15.4mph and 3=20.7mph! OK unloaded but more than I thought.

This was with a fully charged 37v battery so about 42v hot off the charger. To check the amps I briefly stalled the motor on the brake and was surprised/shocked to see a 20amp draw for a not inconsiderable 840W peak I thought his was supposed to be a 15amp controller.

My Lipo RC battery was dead easy to reconfigure for 10s2p 12Ah. Even though the packs are marked 5Ah they give 6Ah in use. I had to buy another PSU to use in series with my original one to get to the required voltage for charging but I'll post about that later...balancing will prove interesting...I really need a good BMS.

I still have to splice the motor wire and put in some connectors to facilitate easy wheel removal...photos to follow later...

 

[Old Timer]

Not much has happened on my re-build as I've had a paint brush stuck to my hand for the last two weekends. However, these arrived a few days ago:



from powerwerx.com in the USA, prompt shipping arrived in about a week. I couldn't find a UK supplier...maybe just didn't look hard enough. Anyhow I managed to build up my new wire loom for the battery, I think I'm going to have to reduce the number of connections a few too many and my CB is now overrated so I need a new one at 15Amps.

Also my new batteries arrived from Hobbyking, now I can experiment with different voltages and see how it affects performance.

Are those batteries small or did you take those cables from the national grid reminds me off when I used to run hundreds of watts mobile with the amateur radio.

 

[NRG]

Oh those batteries are tiny tiny ones but they pack a bit of a punch witha 25C discharge rate so the pipe has to be able to take it.