ZOMGVTEK's 2011 Build Thread...

[ZOMGVTEK]

The lead is out of useful life, so its time to swap in something a bit lighter.

The build will be 20AH @ 44.4V of Turnigy LiPo packs, thats 12S4P of 5AH cells, or 2S4P of the 6S packs.
1000W GM Rear Hub
15 FET GM Controller, moded to 65A
BM-6's, 1/2 grip twist throttle, cruse control, Watts-Up

I intend on drilling some holes in the motor covers, and wiring everything up with 10 gauge high temp silicone wire.
I will be adding more pictures as I finish things...

Here is the bike in question. A Schwinn S-60, with about 1500 hard e-bike miles already on it. Its taken some abuse...
I waterproofed the controller, and all the wiring is done aside from the batts. Just waiting a bunch of stuff from china before I can get it electrified.

The rear derailer smashed into the spokes off a jump at 20+ MPH, its done. I had no chain for a little bit, but im trying out this single gear setup. Its not like I plan on pedaling anyways.

Heres my brothers bike. Same parts will be going on this bike, along with my friends old wal-mart special full suspension bike.


The LiPo made it off the boat today, gotta keep a fire extinguisher handy!


2x ECO 6-10 Chargers will be used, one per 6S4P 20AH group


I can only get about 3-5AH out of these 60+LBS of lead... The 3LB of LiPo on top is roughly equivalent...






Questions, Comments, Suggestions, Criticism? Feel free to post.

[AussieJester]

Just one question...44v 20ah you say?...curious why you have like
24? packs of lipo when 44v 20ah is made up of only eight 22v 6s 5ah packs.

Your gunna LoVE LiPO after lead...

KiM

[ZOMGVTEK]

Everything here is 3x more than what one bike needs, I got the same stuff for my brother and friend.

[torker]

Watch it the first time you crack the throttle at 65 amps. I just got my first taste of 15s lipo on a stock 9 fet Infinion modded for approx. 50 amps. More like 35 a once you are rolling. I had 66v lead before and I thought it was keeping up-NOT. First run on lipo put me on my arse so fast I still can't believe it

Nice build btw

[neptronix]

Oh sweet baby jesus.
I just rode on 30a/36v lipo on my MAC motor and was blown away.

65a? If that motor can handle it, that thing's gonna jerk your damn neck with all that torque.
Sounds exciting.

Bring some good torque plates though, lol..

[kfong]

Crap that's a lot a of lipo's. Your fire extigusher won't even make a dent if that pile goes. I doubt if anything short of containment will really be able to put out such a fire.

[ZOMGVTEK]

I was running the same controller before on the lead, and my watts up did say over 3KW peak before... Its fairly good acceleration, but I wouldn't call it crazy. Id love to run 100A 100V, but the budget just wont allow for it. The bike needs to be more powerful than I am, and what it used to do at 2-3KW was impressive. It lugged up bumpy hills faster than I could, or at least not for long.

Only issue with the lead was its HEAVY, large, dies quickly, and only puts out 60A hot off the charger. A few uphill WOT runs and its back to 50A...
Its 14º outside, not exactly prime weather. However, im going to be abusing the bike when the stuff finally ships from China.

[torker]

I put an automotive ammeter in place and it peaked at 55 amps with the lead. I didn't have any ammeter today with the lipo but it wouldn't have mattered. I didn't have time to look at a meter anyway I knew it was different/better before I got through the yard to the street. Then when the front wheel started coming up over and over I was like coool Then it was a great view of the sky

[neptronix]

I was running the same controller before on the lead, and my watts up did say over 3KW peak before... Its fairly good acceleration, but I wouldn't call it crazy. Id love to run 100A 100V, but the budget just wont allow for it. The bike needs to be more powerful than I am, and what it used to do at 2-3KW was impressive. It lugged up bumpy hills faster than I could, or at least not for long.

Only issue with the lead was its HEAVY, large, dies quickly, and only puts out 60A hot off the charger. A few uphill WOT runs and its back to 50A...
Its 14º outside, not exactly prime weather. However, im going to be abusing the bike when the stuff finally ships from China.

Expect your watt rating to go way up.
That lipo may dip like 4 volts whereas i bet your lead pack was dipping 15+v when you hammered on the throttle.
It will deliver the full amount of amps without complaining.

Sounds like fun to me.

[ZOMGVTEK]

Got the power supplies in... It appears like it can handle the about 400W draw from the chargers at max power...





PowerPole'd the chargers and PSU. Some of the stuff finally shipped from China, still waiting for the backordered 4mm HXT's so I dont have to cut off all the connectors on the LiPo.

[ZOMGVTEK]

These PSU's appear to be good quality. Only thing I would want is a sense option, to pull up the voltage closer to the load. It starts off around 15.02V, and dips to 14.9x under 200-400W loads.

Are these the normal PSU's everyone uses? Or do people generally use the actual Mean Well branded ones? I was impressed at how large output caps are used in this supply. It runs the charger at idle for about 5-10 seconds after disconnecting the mains.

No way to tell how they are going to handle being run for hours slightly beyond rated capacity... But the fan looks decent enough, and was on only about 40% of the time while charging at 200W. I really need to make a decent load bank capable of 12-100V at loads ranging from 100-1KW+...

[skeetab5780]

I have to ask out of curiosity, Did you discharge those huge SLA's with that 14awg wire i see attached to them?

great progress on the bikes cant wait to see it all done ( i wish i had all that LIPO

[fechter]

[quote="ZOMGVTEK"]
Are these the normal PSU's everyone uses? Or do people generally use the actual Mean Well branded ones? I was impressed at how large output caps are used in this supply. It runs the charger at idle for about 5-10 seconds after disconnecting the mains.

/[quote]

Those look like the ones I have. I can't really see any difference between them and the genuine Meanwell ones. They are pretty much identical.

[Whiplash]

I have to ask out of curiosity, Did you discharge those huge SLA's with that 14awg wire i see attached to them?

great progress on the bikes cant wait to see it all done ( i wish i had all that LIPO

Hey bud! I haven't. Seen you here in a while! This is Bryan from youtube! Glad to see you are still into these money pits! How's yours doing?

[ZOMGVTEK]

I have to ask out of curiosity, Did you discharge those huge SLA's with that 14awg wire i see attached to them?

great progress on the bikes cant wait to see it all done ( i wish i had all that LIPO

Yep. I was only running about 65A peak hot off the charger. It would dip down to 40ish fairly rapidly...
Wire never really got warm, unless the batts were fresh and I was at WOT lugging up a steep hill.

But yes, probably was a solid 1V drop under a 60A load... Im trying to do things a bit better this round, since im not rushing to get it together. I dont think I want to deal with anything past 10AWG, but I do have a serious amount of 8GA laying around with some THICK insulation...

[ZOMGVTEK]

Picked up some stainless hardware, I intend on running this through the frame. Probably 2 of these through the frame to hold the extruded L in place...



This is going to be sitting slightly above the controller, and secured by the above bolts. Not worried about the frame exploding from 2-3 small holes.



This is one possible method...



Or if clearance is a issue, this might have to do.

I need to look around for some good ways to hold the batteries together and firmly secure them... The aluminum L stuff will work great to hold the assembly to the frame, but i'm not sure how I plan on holding the batts to the L just yet... Considering some sort of clear heat shrink, then securing the L...

[AussieJester]

I need to look around for some good ways to hold the batteries together and firmly secure them... .

Double sided tape or velcro is what the RC crowd use. There's always Duct Tapeâ„¢ Personally i prefer Gaffer tape
or 'Race Tape' as its commonly called in motor racing circles, to wrap packs in for protection and/or holding them together.

KiM

[Whiplash]

I would use caution running bolts completely through the aluminum frame, you will have a hard time getting the bolts nice and tight without crushing the tube.... If you have to do it this way, get some sleeves for the frame to keep it from crushing!

[ZOMGVTEK]

My lead was attached solely by tape, lol. It really left some brutal residue on the frame thats a lot of work to get rid of...

Id prefer a more mechanical means of securing the batteries, rather than just tape. I dont want to have to worry about them falling off or sliding around like I did with the lead.
Sure, they dont weigh nearly as much, but its just a poor solution if you ask me. If I come up with nothing, tape it is!

And I will see how much the frame distorts when crushing down on it. I dont plan on putting much force on the screws, and my friend did this on his frame and it worked OK... With locking nuts, thread lock, and care, it should be fine. if it isnt, I will find a spacer.

[Gordo]

I don't know for sure, but I am told this is the bad clone with half the guts missing.

PS BAD.JPG (32.25 KiB) Viewed 684 times

And this is the better one.

PS GOOD.jpg (27.45 KiB) Viewed 684 times

[skeetab5780]

sorry i didnt see your reply lash! i tend to hide from the cold weather like a b!tch but im getting ready for my first ride of the season! 3/31/11 no gas day. Ill be commuting to work from my new house which is a little over 10 miles to work ( where i can charge) great progress on the bike! lipo = huge grinnn

[Whiplash]

Yeah, I am making some good progress, wait till its video time!

O.P. how is it coming?

[ZOMGVTEK]

Still waiting on parts from China... The 4MM HXT's finally shipped a few days ago, hopefully they show up in a week or two.

The BM-6's are still on backorder... I might need to look into alternatives for a LVC alarm.

[Whiplash]

Why not just set your controller LVC to a safe point till the get here? I NEVER had a problem doing so on my bike and its got over 1000 miles of use thus far! Better for the pack anyway, it keeps you from going too low and you get more cycles out of it...

[ZOMGVTEK]

I don't think its really a big deal, but I was told monitoring individual cell voltages is the only way to go...

I plan on getting the thing ready to go as soon as I can, but im still waiting on the wire and connectors.