Search found 35 matches

by Jan-Erik-86
Sep 16 2019 11:30am
Forum: Battery Technology
Topic: New 14s battery pack, US18650VTC6 vs NCR18650GA
Replies: 0
Views: 51

New 14s battery pack, US18650VTC6 vs NCR18650GA

I've abandoned my first thought on simply adding some high power cells to my old pack, and have decided on making a new pack. I have a DD hub motor with a shunt modded KT controller which pulls up to ~50A from the battery, but my load is normal in the range of 600-1000W. I mainly use the bike for co...
by Jan-Erik-86
Sep 12 2019 10:28am
Forum: E-Bike Technical
Topic: Sudden Battery Cutoff?
Replies: 4
Views: 125

Re: Sudden Battery Cutoff?

No need to measure more for now id say. Charge up and balace, go for a medium long ride, recheck cell balance. If that same cell is low, youve found your issue.
by Jan-Erik-86
Sep 03 2019 2:40am
Forum: Battery Technology
Topic: Adding high power cells to old pack to compensate for voltage sag
Replies: 1
Views: 104

Adding high power cells to old pack to compensate for voltage sag

My e-bike have an old 20Ah 7p13s pack with generic Chinese cells. This pack still measured around 17Ah about half a year ago, but while it have enough capacity left, the internal resistance is high, and so i have a high voltage sag as well as significant battery heating with high load over time. Whe...
by Jan-Erik-86
Jul 24 2019 2:41pm
Forum: Battery Technology
Topic: How safe is adding an active balancing board?
Replies: 1
Views: 188

How safe is adding an active balancing board?

As thew title say, I'm curious about the safety of adding an active balancing board. As my 12p 13s pack (one 7P and one 6P in parallel) is a mix of used cells it will naturally run out of balance quicker then a pack with identical cells. In the beginning with a 26A controller there was no problems, ...
by Jan-Erik-86
Jun 03 2019 5:20pm
Forum: E-Bike Technical
Topic: Upgraded phase wires, but lost torque at low speed?
Replies: 13
Views: 547

Re: Upgraded phase wires, but lost torque at low speed?

So after several hours work I've redone the LCD+throttle connectors, and used thicker wires time so they won't fail again. 24awg wire is space efficient for signaling wires, but man are they fragile... Also inspected the hall connectors more carefully, and indeed there was a bad connection. Not in t...
by Jan-Erik-86
Jun 02 2019 5:14pm
Forum: E-Bike Technical
Topic: Upgraded phase wires, but lost torque at low speed?
Replies: 13
Views: 547

Re: Upgraded phase wires, but lost torque at low speed?

Is that really so bad? My measurements were a bit off, it's closer to 125cm long from PCB to motor winding. There's only one spade connector the entire way, and it's a larger type, but either way that's only temporary until the XT150 arrive. Either way, while i was inspecting all the connectors for ...
by Jan-Erik-86
Jun 02 2019 7:03am
Forum: E-Bike Technical
Topic: Upgraded phase wires, but lost torque at low speed?
Replies: 13
Views: 547

Re: Upgraded phase wires, but lost torque at low speed?

I see, thanks. The new solder joint were already checked and are good, but I will recheck the connectors, and possibly just solder them while i wait for the XT150 to arrive. Will recheck the old solder connection between the 0,75mm2 and 1,5mm2 wire though, and maybe just solder the 4mm2 wires direct...
by Jan-Erik-86
Jun 02 2019 5:38am
Forum: E-Bike Technical
Topic: Upgraded phase wires, but lost torque at low speed?
Replies: 13
Views: 547

Re: Upgraded phase wires, but lost torque at low speed?

Thanks for the replies guys! The stock wiring from the motor is still connected, I simply hooked onto the phase wires right outside the motor. This is how I had it previously as well though, with the 1,5mm2 phase wires, and it worked fine. When I replaced the 1,5mm2 wires with 4mm2 wires, I simply c...
by Jan-Erik-86
Jun 01 2019 5:30am
Forum: E-Bike Technical
Topic: Upgraded phase wires, but lost torque at low speed?
Replies: 13
Views: 547

Upgraded phase wires, but lost torque at low speed?

Hi guys, My bike is a 26" with a 1000W DD hub motor. Specs unknown, but top speed with wheel off the ground and fully charged 48V/13s battery is around 60 km/h. I originally had a 26A KT square wave controller that i shunt modded to give around 36A, and at the same time i added some additional 1.5mm...
by Jan-Erik-86
May 28 2019 12:35pm
Forum: E-Bike Technical
Topic: Upgrading KT controller, unsure how to wire it up to LCD3
Replies: 12
Views: 798

Re: Upgrading KT controller, unsure how to wire it up to LCD3

Just an update here; The pin-out for the PAS connector were indeed different on the two KT controllers. Swapped wires and PAS works perfectly! :)
by Jan-Erik-86
May 25 2019 12:22pm
Forum: E-Bike General Discussion
Topic: Upgrading chainset on Cannondale F6 - how large can i go?
Replies: 12
Views: 444

Re: Upgrading chainset on Cannondale F6 - how large can i go?

Thanks for all the helpful feedback guys! :) As for PAS vs throttle; I have a throttle, but i choose to mainly use PAS to appear "legal". EU law state motor can only help when pedaling. I ride trough the city daily, so i don't want too much attention when i'm there. I haven't been able to find a 6-s...
by Jan-Erik-86
May 24 2019 4:02am
Forum: E-Bike General Discussion
Topic: Upgrading chainset on Cannondale F6 - how large can i go?
Replies: 12
Views: 444

Upgrading chainset on Cannondale F6 - how large can i go?

Hi, I currently have a Cannondale F6 bike with a 1000W DD hub motor, a 6-speed freewheel, and a 42-32-22 chainset in the front. My problem is that this gearing works fine until around 30-32 km/h, but once past that i need to pedal at an excessive speed to help the motor, and for the most part i end ...
by Jan-Erik-86
May 07 2019 2:32am
Forum: E-Bike Technical
Topic: Upgrading KT controller, unsure how to wire it up to LCD3
Replies: 12
Views: 798

Re: Upgrading KT controller, unsure how to wire it up to LCD3

The PAS connector is still original, so it's unlikely that it have anything to do with the new connectors i've put on. I wouldn't assume that the PAS connector uses the right wiring sequence. Thank you for the heads up on this. I just assumed they were standard from one KT controller to another, so...
by Jan-Erik-86
May 01 2019 2:03am
Forum: E-Bike Technical
Topic: Upgrading KT controller, unsure how to wire it up to LCD3
Replies: 12
Views: 798

Re: Upgrading KT controller, unsure how to wire it up to LCD3

I ended up cutting the connectors off and making new connectors and everything ended up fine, with the exception of PAS. PAS sensor is connected, and the LCD3 is unchanged when it comes to settings, but there is stil no response when turning the pedals (regardless of direction). The PAS connector is...
by Jan-Erik-86
Apr 09 2019 6:56am
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

I've now been pedaling around for about 500 km since the shunt mod, and everything works perfectly as it should. After a 1.5 hour trip today, also with some hills and several start and stops, the controller FETs never got above 35c. So, just curious, as it appears the FETs are able to stay really co...
by Jan-Erik-86
Mar 08 2019 1:06pm
Forum: E-Bike Technical
Topic: Upgrading KT controller, unsure how to wire it up to LCD3
Replies: 12
Views: 798

Re: Upgrading KT controller, unsure how to wire it up to LCD3

Thank you very much for the info! :) I agree it's a downgrade as far as the connectors go, but it's an upgrade from square to sine, as well as from 12x STP80NF70 FETs (68 V, 0.0082 Ω, 98 A) to 18x IRFB3306 FETs. The current controller is shunt modded, so they will deliver the same power, but I'm thi...
by Jan-Erik-86
Mar 08 2019 9:30am
Forum: E-Bike Technical
Topic: Upgrading KT controller, unsure how to wire it up to LCD3
Replies: 12
Views: 798

Upgrading KT controller, unsure how to wire it up to LCD3

Hi, I'll soon be replacing my square wave controller (kt48zwsrl-zc21) with a sine wave controller (kt36/48svprk-sls02e), but while both are from KT and are compatible with the LCD3, they don't have the same connectors. My current controller have battery, PAS, a 9-pin connector for the motor, and an ...
by Jan-Erik-86
Feb 25 2019 8:26am
Forum: E-Bike Technical
Topic: Battery charger or battery issues?
Replies: 4
Views: 254

Re: Battery charger or battery issues?

Sounds like the bms have disconnected the battery, but the reason could be many. It could be a bad cell/group, or a faulty bms, or simply an overdischarged cell group (little likely if it was used just a week ago, but possible if battery is not balanced properly). When you used it last, you didnt by...
by Jan-Erik-86
Feb 25 2019 7:55am
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

Thanks! Yeah there was a bit much thermal paste, but i reapplied it after replacing the phase wires, so now it looks much more clean. It's none-conductive though, so no risk of shorting anything. :) And yeah, the phase wire holes on the PCB would take at least 2.5mm2 wires, maybe even 4mm2. You say ...
by Jan-Erik-86
Feb 25 2019 5:42am
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

Did some more testing today, and went for a ride around 12km with medium/high power usage, significantly more then I'd ever normally need. Start temp was around 12c before i went outside. Outside temp was around 4c. After the ride, the max temp the FETs reached was around 18c, so cold in fact i had ...
by Jan-Erik-86
Feb 24 2019 5:34pm
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

I've now added some phase wires and done another quick test. I still left the stock (0.75mm2?) phase wires in place, but i also added new 1.5mm2 wires all the way from controller PCB to right before the hub. Nothing blew up, and nothing got warm, but I'm not sure how to read my "new" power usage dat...
by Jan-Erik-86
Feb 23 2019 6:03pm
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

Thank you for the advice, I am trying to be careful. :) Outdoors I tested with using PAS first, gradually increasing it from level 1/5. Seeing that PAS 4/5 now give around same power as 5/5 would before mod, i gave 5/5 a go and it read around 36A/1600W. No parts got hot to the touch after 5-10 minut...
by Jan-Erik-86
Feb 23 2019 5:27pm
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

I'm not sure exactly how many amps it will handle, but know its ok at 0.5c long term, and i expect it to be ok at bursts of 2c or so. so about ~14a long term and ~50a burst for a few sec. I removed that small wire that was already there to enhance the PCB traces, and soldered on a thicker copper wir...
by Jan-Erik-86
Feb 23 2019 11:40am
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

I tested the controller now, and it apears to draw around 24-25A peek when LCD3 show ~1050W and battery is down to about 50% SOC. Eventually got the controller out and apart. It's a 12-FET controller, and It looks like the PCB traces have been slightly enhanced, but there is for sure room for huge i...
by Jan-Erik-86
Feb 23 2019 9:19am
Forum: E-Bike Technical
Topic: Increasing controller power to my 1000W DD hub motor
Replies: 28
Views: 1514

Re: Increasing controller power to my 1000W DD hub motor

Thank you for all the replies guys! :) By the way, does anyone know the pinout of this connector? I couldn't find this exact connectors pinout. Phase wires are obvious, but i'd like to know the rest to make things a bit easier.. :) I guess if i'm aiming at no more then around 2kw peek, there is not ...