Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Aug 21 2018 12:58pm

amberwolf wrote:
Aug 21 2018 12:22pm
wturber wrote:
Aug 21 2018 3:51am

So I spent last week layering on about five or six coats of orange-ish yellow paint (a couple coats each morning) to make sure the black was well covered and then topped it off with some clear for a bit more durability (and shine).


FWIW, Krylon white primer (and probably most others) would cover the black right up, and help the color paint stick well. :)
I used Kryolon Fusion - which supposedly sticks to plastic really well. Multiple coats were cheaper than buying an extra can of primer. Though I admit I splurged on the clear coat. :D
Last edited by wturber on Aug 21 2018 3:14pm, edited 1 time in total.
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Aug 21 2018 1:07pm

fechter wrote:
Aug 21 2018 12:32pm
I've seen guys that put a piece of plywood or Lexan in the bottom of the plastic crate to stiffen it up. Maybe under the bottom in your case.
I almost put in a plywood bottom since I have a fair bit of that in different thicknesses. But I wanted to keep the ability to attach bungees to/thru the bottom. I have stronger bits of aluminum if the umbrella parts don't hold up. But I have many more umbrella parts and they cost me nothing other than storage space. In fact, I wish I had remembered I had them when I was reinforcing my rack. Drat!
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Aug 22 2018 12:15pm

Oh - I forgot to mention that the DD hub now has ferrofluid in it. I'd like to say Statorade®, - which is what I thought I was buying from Lunacycle since they use the Statorade® trademark on their website and the shipping from Grin was a pretty silly amount. I assumed that they were just white-labeling the product from Grin. But it seems much more likely that they are just abusing Grin's trademark - which Grin seems pretty unconcerned about since they don't include the trademark symbol on their website or their packaging.
(http://tmsearch.uspto.gov/bin/showfield ... el1jyy.2.1)

But anyway, since I had the wheel off to install the larger 180 mm disc rotor, I went ahead and opened up the motor, so that I could seal the covers and add the ferrofluid directly - thus avoiding drilling a hole and reducing the likelihood of leaks. That said, I should have drilled a hole in one of the rotor mount holes while I had it apart. Drat! Maybe next time.

I wanted to measure the lamination thickness, but the motor core seemed seemed to have a strong attraction to the motor's magnetic ring. I decided it wasn't worth the effort to try to force it free and potentially damage a motor that was working perfectly fine as it was. So I counted the magnets and windings and took a few pictures for posterity, and sealed it up.

Anyway, I can't say that I can observe any difference. Hopefully this lets the motor shed a bit more heat when climbing hills in the summer.


IMG_20180818_083624137_LL_cr_SM.jpg
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Aug 25 2018 2:15pm

I sent an message to the ebay seller with picture explaining why I thought the MOSFETs were fake. They sent an email back explaining that their 3rd party source claims they are real. Well duh! What else would they say? Kinda funny.

Trying to be fair, I sent an email (with photo) to NCE figuring that while I'm sure they could care less about my order, they might be interested in a distributor that is selling many more counterfeits. They have not responded. I also sent a follow up email telling the ebay seller that it is kind of silly to just take their distributor's word. Maybe they should check with NCE if they care about selling fakes.

Of course, maybe I'm all wrong and the phony looking logo is legit? Seems unlikely.

Anyway, my main concern at this point is getting a definitive idea of whether they are fake or not. I consider the money trivial and won't ask for a refund unless I'm sure that they are fake. So I went ahead and soldered one of the FETs back into the booster and the booster is now working again. In fact, the output voltage was exactly 54.0 volts - exactly what is was set before the failure. That doesn't mean the FET is legit, but it does show that the FET was the proximate cause of the booster ceasing to work. Now that I know that, I'll look for a legit source for a legit replacement FET and, buy some new capacitors and complete the repair.

Oh - I upgraded my shifter to a legit 7 speed index shifter this morning as well.
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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Alan B   100 GW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by Alan B » Aug 25 2018 3:12pm

Ebae is very hard on fakes, not that you are concerned about a refund. But the seller probably knows this and it could hurt them.

The voltage value is not really dependent on the FET, as long as it acts like an FET.

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Aug 25 2018 4:27pm

Alan B wrote:
Aug 25 2018 3:12pm
Ebae is very hard on fakes, not that you are concerned about a refund. But the seller probably knows this and it could hurt them.

The voltage value is not really dependent on the FET, as long as it acts like an FET.
Good to know about the voltage. The logo is so phony, that I'm personally convinced that these are bogus. I know very little about electronics, but in my years doing graphics and animation I have learned that companies are almost always VERY particular about how their logo is displayed and used. They usually have standards books on this. So it seems almost unthinkable to me that the phony baloney imitation logo actually came from NCE. OTOH, its a Chinese company and maybe their sensibilities are different?

Anyway, my personal conviction on this isn't proof. If I could prove them fake, I'd be happy to report the seller, give 'em a poor rating etc. just to warn others off. It isn't like they seem very concerned about the truth of this matter. But I'm hesitant to state that these are phony without some outright proof. Too bad NCE also seems to not care.

I might install this "repaired" booster on the bike tomorrow and see how it performs (does it run hot, sag, fail?) and also check to see if I can blow it up with normal use. Not sure what that would prove. Probably nothing. But I'm curious and I have four more. :^)
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Oct 27 2018 1:04pm

I pulled into the parking lot at the studio this morning and my odometer had just hit 4999.9. So I rode one lap around the parking lot to hit an even 5000 miles.
5000_miles.jpg
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by docw009 » Oct 27 2018 3:43pm

Are you still running that bike on a bunch of 36V4AH batteries. After a year, all five of mine are still quite useable. I only use them two at a time.

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Oct 27 2018 5:09pm

docw009 wrote:
Oct 27 2018 3:43pm
Are you still running that bike on a bunch of 36V4AH batteries. After a year, all five of mine are still quite useable. I only use them two at a time.
Yes. I'm running eight at a time. Four in each of two plastic cases mounted as panniers.

Tomorrow, I might do a quick overview of the bike comparing the current configuration with my original setup. It is fundamentally the same. I've just slowly made additions and modification to make things more practical and usable.
IMG_20180514_010818263_LL_SM.jpg
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by markz » Nov 12 2018 4:21am

I've been thinking about this on the long walk home with no chain and no juice left 36V pack, 42V max, 32V LVC, unknown Ah so old now, 10S12P. 36Ah 36V 100A cont is 20 or 30A I dunno, also so old.

Why was I thinking about this? Because I have a 5S2P (21V 3Ah 10A) tool pack battery on my handle bar for my light.

Run light, run usb charger, and run DCDC conv.

Now I wonder with one tool pack battery that I have using a DCDC
21V 3Ah 20A pack which is 420W
+
DCDC
=
42V 1.5Ah?????? 10A?????? which is 420W!
63Wh @ babying it 25Wh/km, minus inefficiencies of lets say 10% so round to 55Wh @ 25Wh/km so 2km.
That would have saved the sweat that happened and is a rare sight. :oops:
I have a much smaller DCDC, no fins, probably 10A model, only 2 caps if I remember correctly. Might be 4, I dunno.

edit
Thinking about this now, 5S2P might as well be 5S1P 1.5Ah battery alone. Sure its more work, or spend $20, nah.
Or just have a reserve pack.

PS
Great project you got though!

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Nov 15 2018 12:22pm

I wouldn't buy a voltage converter so you could use your smaller battery to power the bike in an emergency. It isn't enough extra help for the size, weight, cost and trouble. I suggest just adding to your battery pack ... and installing a chain. That's been my approach.

As for the chain, I've had two chain incidents in about 5400 miles of riding that I repaired on the side of the road. I carry a spare link and a chain tool. I don't need a chain for about 98% of my ride, but I do for some steep hills and I like to pedal anyway. I know you don't care to pedal. But you can just put it in a granny gear and other than the freewheel ratchet noise have a similar effect. Alternatively, you could carry a chain with a spare "missing link" and install the chain in case of emergency. Beats walking.

BTW, broke a spoke today in the rear (motor hub) wheel. That's the second one. It's been about 800 miles since the last one.
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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wturber   100 kW

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Re: Using the Wangdd22 1500W 30A DC Boost Converter on an ebike

Post by wturber » Nov 19 2018 12:23pm

So I decided to replace my broken spoke yesterday and had to remove my rear wheel since I had to remove the tire to be able to replace the spoke. I'm glad I did. I found two spots where the tire had worn down to the fiber belts. One had almost worn through the belt as well!! I was wondering where I had skidded the tire that severely and couldn't remember anything like that. Then I spotted the other, less severe and longer spot. Wow! I had simply worn through the tread. My first thought was that this seemed awfully fast. But further investigations showed I got this tire in early November last year when my bike had about a thousand miles on it. I'm now at almost 5500. So the tire gave me nearly 4500 miles of wear. This seems to be on the lower/middle end of what Schwalbe says to expect from their pretty durable Marathon series. So I guess this tire lasted as well as could reasonably be expected.

Anyway, I put a knobby off-road tire (that came with the bike) on the back wheel for now. Time to go tire shopping.
RibMO_wear2.jpg
RiBMO_wear1.jpg
"Commuter - DC Booster"
Iron Horse 3.0 hardtail - 48V / 1000W / 470rpm generic Chinese DD Hub motor (ebay)
8 x 36v 4.3ah 10s 2P battery packs - 1500W 30A DC Boost Converter delivers 54v and about 1000 watts peak
53T/42T Sakae Road cranks - 30mph+ on flats
viewtopic.php?f=2&t=90369

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