I'm still pretty new at putting together an ebike (this is my second one). I thought I'd describe my plans, solicit comments, and report on how everything worked together (after I finish).
Bike: SE Big Mountain 29er - 3x7 speed, suspension fork, steel frame - seems well made (brakes are the only thing I'm considering upgrading) http://www.nashbar.com/webapp/wcs/stores/servlet/mProduct4_10052_10053_584252_-1_catNav
Controller: Grinfineon C7240 (auto hall mapping, but not sine wave, 72v, 40a)
Motor: new Mac 12T (with temperature sensor) geared rear hub motor with 7 speed freewheel.
Cycle Analyst: CA3-DPS - plan to update to 3.1 firmware
Torque Sensor: TDCM 120mm (2.5 mm smaller than the bottom bracket that came on the bike, but I think everything fits fine)
Battery: homemade 20s7p 26650 LiFePO4 - big and heavy, but seems reliable and will hold nearly 2KWH - also very cheap. I have the cells necessary to take this to 24s7p and may do that.
Misc: nice ebrake levers from ebikes.ca -- seem to be an upgrade though I had to modify the clamp that holds the shifters so that they'd fit together, throttle from em3ev (which I may not use much, relying instead on the TDCM torque sensor), 3 position switch, headlight that works at up to 80v (cheap ebay part), taillight from Nashbar that charges from USB (which I may power from my batteries)
I have most of this put together except for the cycle analyst -- I destroyed my old one trying to add a speed sensor and only just now ordered the new one. One thing I'm not to clear on is what I need to do to hook up the temperature sensor in the motor (a sixth wire in the set of hall wires) to my cycle analyst. Can I just hook up the single output wire from the motor or do I need to do something with the other wire on the cycle analyst temp sensor cable? I've hooked up the controller and the motor and verified that the auto hall mapping seems to have worked fine. I've not made the final connections, I'm going to shorten the cables and crimp new connectors.
The bike I'm using is one of the cheapest new bikes I could find with decent quality. It's at the bottom of "decent' quality category, perhaps, but it's a big step up from department store bikes. Seems a comfortable ride and I think the front suspension will be nice on the constant potholes over my commute.
The motor was selected based on my need for some serious hill climbing. Plus I have no desire to go over 30mph (probably not even close to that most of the time) which I think I can achieve with my battery & controller.
The battery is kinda big and heavy, but I think I can get a whole week out of a single charge. It's just about the only thing saved from my previous bike. I have it loaded in some cheap but sturdy Roswheel panniers hung on an inexpensive delta rack. It's well padded and protected. I bought a bms for the battery, but I've never actually wired it up. So far, my battery is arranged in 4s7p (nominal 12v) batteries that I'm charging with a balancing RC charger. I'm considering not hooking up the bms and just getting more of the RC chargers so that I can charge all the batteries at the same time using them.
Any comments or suggestions?
Bike: SE Big Mountain 29er - 3x7 speed, suspension fork, steel frame - seems well made (brakes are the only thing I'm considering upgrading) http://www.nashbar.com/webapp/wcs/stores/servlet/mProduct4_10052_10053_584252_-1_catNav
Controller: Grinfineon C7240 (auto hall mapping, but not sine wave, 72v, 40a)
Motor: new Mac 12T (with temperature sensor) geared rear hub motor with 7 speed freewheel.
Cycle Analyst: CA3-DPS - plan to update to 3.1 firmware
Torque Sensor: TDCM 120mm (2.5 mm smaller than the bottom bracket that came on the bike, but I think everything fits fine)
Battery: homemade 20s7p 26650 LiFePO4 - big and heavy, but seems reliable and will hold nearly 2KWH - also very cheap. I have the cells necessary to take this to 24s7p and may do that.
Misc: nice ebrake levers from ebikes.ca -- seem to be an upgrade though I had to modify the clamp that holds the shifters so that they'd fit together, throttle from em3ev (which I may not use much, relying instead on the TDCM torque sensor), 3 position switch, headlight that works at up to 80v (cheap ebay part), taillight from Nashbar that charges from USB (which I may power from my batteries)
I have most of this put together except for the cycle analyst -- I destroyed my old one trying to add a speed sensor and only just now ordered the new one. One thing I'm not to clear on is what I need to do to hook up the temperature sensor in the motor (a sixth wire in the set of hall wires) to my cycle analyst. Can I just hook up the single output wire from the motor or do I need to do something with the other wire on the cycle analyst temp sensor cable? I've hooked up the controller and the motor and verified that the auto hall mapping seems to have worked fine. I've not made the final connections, I'm going to shorten the cables and crimp new connectors.
The bike I'm using is one of the cheapest new bikes I could find with decent quality. It's at the bottom of "decent' quality category, perhaps, but it's a big step up from department store bikes. Seems a comfortable ride and I think the front suspension will be nice on the constant potholes over my commute.
The motor was selected based on my need for some serious hill climbing. Plus I have no desire to go over 30mph (probably not even close to that most of the time) which I think I can achieve with my battery & controller.
The battery is kinda big and heavy, but I think I can get a whole week out of a single charge. It's just about the only thing saved from my previous bike. I have it loaded in some cheap but sturdy Roswheel panniers hung on an inexpensive delta rack. It's well padded and protected. I bought a bms for the battery, but I've never actually wired it up. So far, my battery is arranged in 4s7p (nominal 12v) batteries that I'm charging with a balancing RC charger. I'm considering not hooking up the bms and just getting more of the RC chargers so that I can charge all the batteries at the same time using them.
Any comments or suggestions?