Search found 44 matches

by Firedog
May 28 2020 12:42am
Forum: E-Bike Technical
Topic: Reducing controller's current
Replies: 4
Views: 131

Reducing controller's current

I built a tandem using a Crystalyte 5303 front hub and 4840 controller running 54V. It has a 3 power level switch, a Clite cruise control and a thumb throttle. Even in low power, it's more than I want and the bike wants to go faster than 20 to 28mph range we like. In high power, it delivers the 40a ...
by Firedog
May 28 2020 12:06am
Forum: Battery Technology
Topic: Fast Charging - What is the secret?
Replies: 36
Views: 2067

Re: Fast Charging - What is the secret?

Tool batteries charge at successfully at very high rates. Makita 18V chargers charge at 9 amp maximum. Their secret is good engineering and design. The the batteries surface area/weight ratio is many time that of a ebike battery. The design is rugged from the sturdy weld grids and the close fitting,...
by Firedog
May 16 2020 1:00pm
Forum: E-Bike General Discussion
Topic: Diagnosing Controller w/ Ebike Tester
Replies: 13
Views: 404

Re: Diagnosing Controller w/ Ebike Tester

30v battery voltage? That's below the LVC on many 36v controller.
by Firedog
Apr 19 2020 2:40pm
Forum: E-Bike Technical
Topic: Can't make simple PAS work
Replies: 4
Views: 155

Re: Can't make simple PAS work

Yes, both directions..... but not for long enough!! It starts after 2 or 3 cranks in reverse. Thank you, so much.

I'll have figure how to remount the PAS to give the controller the direction it wants. Or is there a better way?
by Firedog
Apr 19 2020 12:08pm
Forum: E-Bike Technical
Topic: Can't make simple PAS work
Replies: 4
Views: 155

Can't make simple PAS work

I've built dozens of kit ebikes. I've never been a fan of simple cadence PAS finding a throttle with cruise control and several levels of power better. I doing a build now that requires PAS, but I can't make it work. I tried 3 controllers that have both throttle and simple crank mounted, magnet acti...
by Firedog
Jan 07 2020 10:50am
Forum: E-Bike Technical
Topic: 2000W 48-72V DC brushless controller wiring help
Replies: 16
Views: 741

Re: 2000W 48-72V DC brushless controller wiring help

The orange and gray wires are likely cruise control: Similar controller https://www.ebay.com/itm/48-72V-1500W-Electric-Bicycle-E-bike-Scooter-Brushless-DC-Motor-Speed-Controller/183306034669?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D4ca3ce6fb3b747388e32c7dd61d...
by Firedog
Jan 07 2020 2:11am
Forum: E-Bike Technical
Topic: Crystalyte 3640 and 4840 controllers
Replies: 4
Views: 321

Re: Crystalyte 3640 and 4840 controllers

Climbing a long grade immediately pushes the power to 40-45 amps even in the low switch position and min. cruise setting. Amberwolf, I'm totally wrong on that report. What actually happen was I went full throttle to get up some speed ahead of a steep hill, set the cruise control, and didn't get the...
by Firedog
Jan 06 2020 2:44pm
Forum: E-Bike Technical
Topic: Crystalyte 3640 and 4840 controllers
Replies: 4
Views: 321

Crystalyte 3640 and 4840 controllers

I bought several of these (NOS) from a local bike shop. The 3640 and 4840 boards (EB212-A-5 ) and components seem identical except for one of the two power resistor (10w?). I assume it controls the LVC. 300ohm for the 3640; 330ohms for the 4840. Question #1: Can I change that resistor to make a 3640...
by Firedog
Jan 06 2020 2:33pm
Forum: E-Bike Technical
Topic: Using REGEN on Crystalyte CT4840 v2 Controller
Replies: 5
Views: 975

Re: Using REGEN on Crystalyte CT4840 v2 Controller

6 years for a response! I have several 4840 and 3640 controllers with the same boards as your pictures. They do support regen braking if the solder hole marked Bk is grounded. Applying the brakes will activate the brake sensor switch and cut the throttle and engage motor braking if the speed is suff...
by Firedog
May 31 2019 8:08am
Forum: E-Bike General Discussion
Topic: Why do Hall Effect Sensors break? (UPDATE, AGAIN w new 5404)
Replies: 27
Views: 6122

Re: Why do Hall Effect Sensors break? (UPDATE, AGAIN w new 5404)

I had all 3 Hall sensors fail in a 5303 after the motor worked fine on the bench. It turned out a red(+) wire was shorted to the axle. New Halls and fix the short was the solution. I had tested all 5 hall lead wisre combinations for shorts but didn't think to check for a short to the motor. I hope y...
by Firedog
May 29 2019 2:20pm
Forum: E-Bike Technical
Topic: Guide: fixing deadband of Wuxing hall throttle
Replies: 3
Views: 1662

Re: Guide: fixing deadband of Wuxing hall throttle

It is a bit difficult to get the snaps to release fully since they bite on the full perimeter. That's "difficult" how about "nearly impossible"! Get a short length of 3/4' pvc sprinkler pipe. It is the perfect OD and the perfect thickness to release the snap. I suppose a piece of 3/4" schedule 40 w...
by Firedog
May 21 2019 1:35pm
Forum: Battery Technology
Topic: Small 36V battery recommendations
Replies: 7
Views: 676

Re: Small 36V battery recommendations

Consider running 2 18v tool batteries in series. Available 2 to 10ah. My choice is Makita because of the simple mount design, compact size, very low price, long life and fast charging (charger's cool cells with fan during charge). Flexible too: bring 2 spares for long rides and you can build the wif...
by Firedog
May 20 2019 11:52am
Forum: E-Bike Technical
Topic: KT-LCD3 display - speed report wrong
Replies: 3
Views: 525

Re: KT-LCD3 display - speed report wrong

couldn't match my GPS until I added the external sensor Thank you! Instead of ordering and waiting for a external speed sensor, I pulled a PAS sensor and an old spoke magnet out of my parts bid. It works perfectly. I set up this tandem to use a Crystalyte 5303 or a much lighter 408. A 5 minute swap...
by Firedog
May 20 2019 9:55am
Forum: Battery Technology
Topic: Using cordless drill batterys
Replies: 11
Views: 1837

Re: Using cordless drill batterys

Where did you find connection boards for the batteries
PM me for DIY instructions or a quote for me to build one.
by Firedog
May 17 2019 6:47pm
Forum: E-Bike Technical
Topic: KT-LCD3 display - speed report wrong
Replies: 3
Views: 525

KT-LCD3 display - speed report wrong

I just installed a KT36/48VPRL controller with a compatable KT-LCD3 display driving a Crystalyte 408 front hub with 54V. The speedometer function is calibrated with a setting for wheel diameter (26,700c,28,29) and P1 (Motor characteristic parameter setting) where P1= motor gear reduction ratio x num...
by Firedog
May 17 2019 6:17pm
Forum: E-Bike Technical
Topic: hub motor hall sensor woes - need help
Replies: 6
Views: 510

Re: hub motor hall sensor woes - Fixed

So all three Hall sensors were fried. I replaced them being careful no lead was grounded or shorted to another. The Crystalyte 5303 motor now works perfectly and wow!. I mounted it to a tandem with a 35A max controller using using 54V it has more power than should should be legal. (It isn't legal in...
by Firedog
May 06 2019 6:07pm
Forum: E-Bike Technical
Topic: hub motor hall sensor woes - need help
Replies: 6
Views: 510

Re: hub motor hall sensor woes - need help

I fixed the one red wire that was shorted to the armature. I re-tested the continuity of all 5 wires from the connector to the sensor; checked that no wire was shorted to any other and that none were still shorted to the armature (ground). All good. Unfortunately, none of the halls will change state...
by Firedog
May 06 2019 3:57pm
Forum: E-Bike Technical
Topic: hub motor hall sensor woes - need help
Replies: 6
Views: 510

Re: hub motor hall sensor woes - need help

Thanks for responding amberwolf. I think you got me on to the right path. I have the wires connected correctly and all beveled edges pointing up. All 5 wires are continuous from the connector to the individual sensor's leg. None of the wires is shorted to any other. None of the wires is shorted to t...
by Firedog
May 05 2019 10:24pm
Forum: E-Bike Technical
Topic: hub motor hall sensor woes - need help
Replies: 6
Views: 510

hub motor hall sensor woes - need help

I have a NOS Crystalyte 5303 front hub motor. I thought it would be interesting connect it to a cheap 72V 1500W Sunwin controller. Bench test was smooth. On the street it was more than interesting; actually a little scary but the bike died climbing the first hill. Turns out one of the motor hall sen...
by Firedog
Mar 11 2019 11:31am
Forum: E-Bike Build Threads / Photos & Video
Topic: Rhoades Car: a design mess: some fixes
Replies: 5
Views: 661

Re: Rhoades Car: a design mess: some fixes

Amberwolf, Thank you for the alternate hub motor mounting idea. Somewhere in ES I saw a hub motor mounted to a frame driving a rear wheel via a chain. I thought the hub was fixed and a sprocket mounted to the axle. I gave up when I realized the wires have to spin with the axle. I couldn't figure how...
by Firedog
Mar 10 2019 8:04pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Rhoades Car: a design mess: some fixes
Replies: 5
Views: 661

Rhoades Car: a design mess: some fixes

I'm not sure if this goes under E-bike builds or somewhere else. A guy that has bought several of my bikes builds brought me a Rhoades Car with some problems. Originally designed as a 4 wheel pedal only, side by side tandem, this model, came with a 24v brushed motor and heavy lead acid batteries. Th...
by Firedog
Jan 10 2019 12:30pm
Forum: Motor Technology
Topic: Inside EPLUS motor after 14,100 kms
Replies: 4
Views: 1090

Re: Inside EPLUS motor after 14,100 kms

Mico13car, I'm trying to open my EPLUS 1000W hub. It looks like you were able to press the center out of the bearing from the cassette side. Did you use a press, heat? Any tips would be appreciated. I really need to access the controller side of the the motor. There is a large circlip preventing rem...
by Firedog
Dec 27 2018 3:08pm
Forum: E-Bike Technical
Topic: $14.99 72v Sunwin Controller
Replies: 503
Views: 61710

Troubleshoot 48-72v 1500w Sunwin controller

I connected the subject controller to a Crystalyte 5303 motor with 72v battery. The only connections used; battery +/-, hall sensor, phase wires, throttle and controller on power wire. The controller has 100V caps and solder pads marked 60v, 64v, 72, 80v. I left those as received. I shop test the co...
by Firedog
Dec 11 2018 1:52am
Forum: E-Bike General Discussion
Topic: Stromer STX1 -> Hack
Replies: 9
Views: 953

Re: Stromer STX1 -> Hack

I believe the STX1 came with the TDCM Ulta, power 48, motor. It has the controller inside. It's very heavy but powerful and totally quiet. Well worth trying to fix. Agreeing with Amberwolf, if you want to keep all the feature of the STX1 you are at Stomer's mercy for part$. You also can't be sure wa...
by Firedog
Dec 11 2018 12:23am
Forum: E-Bike General Discussion
Topic: E-bike Powered by Tool Batteries?
Replies: 16
Views: 3181

Re: E-bike Powered by Tool Batteries?

I was wondering if anyone has made an e-bike powered with batteries from any of the battery powered tools (e.g. Greenworks, Ego, Ryobi, etc). Seems like an interesting way to save on cost (if you already have the batteries) and make the power system modular (e.g. put in one battery pack for a short...