Sorting out my Torq1

[averhamdave]

Rather than continue with the old thread which dealt with identifying problems with my Torq (Duff battery and probably failed Hall Sensors), I have decided to start another to deal with the fix - for which I will doubtless require substantial help!

Frank - Your friend in China, Ge Shijie has responded to my e-mail asking about sensorless controllers for the Bafang motor. This will bypass the need for Hall Sensors I believe. He has confirmed he can supply for $45 to include shipping. He has also said he can supply wiring (I asked that as well) but at the moment am not sure what "wiring" I should be obtaining?

My duct tape battery, hopefully on its way from China will reside temporarily on the Torq rack whilst I establish that the new controller fixes the noise and rough running issues. Eventually I would like to attempt some sort of budget re-cell of the Ezee battery. Same or different battery technology. Surely someone has done this?

I'll keep posting as things develop. Thanks to all who have helped so far.

 

[averhamdave]

After some confusion with e mails crossing over I have finally got my order placed and paid for for the Sensorless Controller with Ge Shjie (ecrazyman).

He has come across as very helpful. The delivered price of the controller "with associated wiring" is £30.

 

[flecc]

Eventually I would like to attempt some sort of budget re-cell of the Ezee battery. Same or different battery technology. Surely someone has done this?

LiFePO4 cells are larger for a given capacity and current delivery than li-ion/li-poly Dave, and that together with the need for a BMS means the space inside the battery case isn't big enough.

The old Torq 1 makes it even more impossible since it's very powerful motor/controller combination is so greedy for current. The 10 Ah battery barely delivers 15 miles in mixed terrain if the power is freely used and some get less, one member barely topping 11 miles with the original new batteries. It really needs the 20 Ah Li Ping batery to deliver it's full performance and that dwarfs the case.
.

 

[averhamdave]

Yes will do. If the new controller really sorts the motor noise out then I'll carry on and possibly go for a rack mounted larger battery. I'll be testing with the 15a one I have coming from China for now

 

[NRG]

It should come from a London postal address, takes about five working days

 

[averhamdave]

My sensorless controller has arrived from Ge Shjie (ecrazyman) and all is ready for me to fit and try.

It is my intention to take power directly from the battery to the controller and generally lash up the installation to establish that the controller does indeed fix the noisy motor problem. If it does then I will install neatly.

The package arrived containing the controller and loose mating plugs/sockets as I had asked for these as well. Unfortunately there is no wiring diagram and to that end I have posted here a picture of what I have. I would appreciate any input (which I will not hold you responsible for!) regarding what wire does what.

I have numbered each group of wires and they are as follows:

1: red, yellow and blue which I'm sure go direct to the motor.
2: largish, white male plug with 3 wires - red, green and black? Pedelc sensor? Battery condition indicator?
3: white male plug, two wires - black and yellow. Brake cut off?
4: small black male plug - 3 wires, red, green and black. Throttle?
5: Large white female socket, 3 pins, large red wire, small red wire, large black wire. Obviously power in from battery but why would there be a 3 rd terminal for the small gauge red wire?

I must point out that I may be totally wrong with my assumptions about what does what.

Thanks for any help,
dave

 

[NRG]

1: red, yellow and blue which I'm sure go direct to the motor.
2: largish, white male plug with 3 wires - red, green and black? Pedelc sensor? Battery condition indicator?
3: white male plug, two wires - black and yellow. Brake cut off?
4: small black male plug - 3 wires, red, green and black. Throttle?
5: Large white female socket, 3 pins, large red wire, small red wire, large black wire. Obviously power in from battery but why would there be a 3 rd terminal for the small gauge red wire?

I must point out that I may be totally wrong with my assumptions about what does what.

Thanks for any help,
dave

1. Phase wires, you may need to swap blue andnyellow, on mine I did not.
2. Throttle
3. Brake cut off
4. Pedelec sensor
5. Battery connection, small red wire is for on / off switch, Vbatt = on

Hope that helps.....

 

[NRG]

Dave sent you a PM. I thought you had a three way switch sent as well, I've corrected my post above....

 

[averhamdave]

Thanks very much for the info and help generally. I'll keep you posted but am sure to have more questions
Dave

 

[averhamdave]

Well work has subsided enough for me to have a couple of hours on the Torq today.

The sensorless controller had turned up as had the 36v, 15a duct tape battery.

Principal objective today was to establish if the new controller which doesn't utilise the hall sensor properties of the motor, would actually run the motor and equally as important run the motor without the terrible noise it had previously emitted.

Strapped the battery to the rear rack. Fitted (temporary) bullet connectors to the output cables. Cable tied the controller to the front of the rack.

I fitted a spare twist throttle to the right hand grip (ezee throttles are usually on the left). This had an adequate cable length to reach the controller.

Ran 3 core, 15a cable between the controller and Bafung motor. Connected the battery to controller via fuse and key switch.

Switched on - Yippee!

Motor feels powerful and is now operating at an acceptable noise level. There is some minor bearing noise but I can attend to that later. The grumbling, grinding noise has gone.

Trouble is I can't test ride, I'm in a snowed up, iced up rural area - hope it thaws soon, can't wait!

 

[NRG]

Good result!

 

[averhamdave]

I still haven't had chance to try to set up due to the weather and road conditions round here - we don't see gritting lorries where I live!

However, I'm assuming that all is going to be OK and am planning what to do next as I finalise the installation of the new equipment. This leads me to a number of questions and any help would, as usual, be appreciated.

The original Ezee power meter was/is damaged beyond reasonable repair. I would like to fit some sort of battery condition indicator and would be happy with LEDs. Failing that a digital voltmeter. I don't want/can't afford at this stage to buy a cycle analyst and have concluded that a Watts Up meter or Tunigy are not a fit and forget installation. Neither am I attracted, at this stage by the idea of heavy gauge wires runing backwards and forwards along the bike. Can I buy a simple LED power indicator set-up! (anyone got a link?) What should I do?

The original Ezee conroller is housed below the battery and somewhat exposed to the elements. It would be sensible to remove it and replace it with the new "e-crazyman" controller but it doesn't look that weatherproof. I don't like the idea of fitting it into a sealed box because of heat problems. Do you concur? I thought about fitting it in a triangular bag under the crossbar as Alien used to do.

Should I wire in the pedelec system? What will it do for me? the hardware exists on the Ezee and the controller provides the facility. Is it worth it given that I will need extra wiring to the handlebars, an additional switch etc?

Thanks, dave

 

[averhamdave]

We've had really bad snow here and its been impossible to get out to try the bike until today really.

Last Saturday I wired in the new controller in place of the original Ezee one. - Removed the battery carrier to which the controller was mounted. removed the original drilled the casing for the different hole spacings and fitted the new one. Looks original now

Completely rewired the bike from front to back. Charged the battery this morning (which I know is weak) and have done a mile or so under power.

Top speed with the new controller, with reasonable rider input was about 20mph so that was good. However the battery started to sag and when I got home I measured the voltage at only 37v

I thought I had a deal going for new battery which is why I was persevering with the bike but that has now fallen through and I am not up for spending £500 on a new one.

Worse than that the noise issue has not gone away. When I lift the front of the bike from the ground and throttle up it is much, much better in terms of noise so I feel that the sensorless controller has made a difference. However cruising at say 12mph on part throttle with the motor barely working the noise level is - to me - unacceptable. The grumbling, grinding noise is still there so I guess the motor is shot as well.

Time to call it a day on that one I think and move over onto the other project!