Ebike Project 72V HS3540 UK "build thread" +Videos!

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rui_fujino   1 kW

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Re: Ebike Project 72V "build thread"

Post by rui_fujino » Aug 17 2011 11:00am

Okay, some people wonder what I'm doing so here is my todo list:
Order either 600w or 900w bulk charger from bmsbattery
Order batteries (8 x 5s 5000mah)
Buy battery master switch

Currently done:
Battery 72v setup wire harness
Lyen Controller programming
Ordered battery medics (balancer)
Upgrade parts for bike

Progress:
Making brake light with micro switch (also ebrake)
Making headlight
Lots of soldering

My estimated aim of 72v setup done day is by the end of SEPTEMBER! :mrgreen:
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V "build thread"

Post by rui_fujino » Aug 21 2011 3:16am

I've got battery medics X4 today! :D since Hobby king were sold out I looked around and turns out ebay has them pretty cheap too!
only $18.58 and free shipping fee!
http://www.ebay.co.uk/itm/260753810568? ... 1439.l2649
IMG-20110821-00151.jpg
battery medic X 4
Last edited by rui_fujino on Sep 02 2011 12:20pm, edited 1 time in total.
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V "build thread"

Post by rui_fujino » Aug 29 2011 10:26am

Its been some time with no progress and no nothing...but im making my moves now :wink:
I'm making my battery orders tomorrow so Give me shout if im making some stupid mistakes! :shock:
8 X T5000.5S.20 - Turnigy 5000mAh 5S 20C Lipo Pack (20s2p)
also spare balancing leads for bulk balance charging.


More pictures and action to come in 3weeks time when Im back in UK! :mrgreen:
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V "build thread"

Post by rui_fujino » Sep 01 2011 9:45am

Great news! i have made the payment for the batteries and balance tabs!
AND EVER BETTER HERE IS BUDDY CODE! :wink:
http://www.hobbyking.com/buddy.asp?code ... 7463613045
this should make your balance tabs cheaper if anyone is needed!
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V "build thread"

Post by rui_fujino » Sep 02 2011 12:24pm

Today i logged in and realised all the pictures has gone!!!! :evil: :x :cry:
since I haven't made much progress with number of pages like others I've decided to re-upload the pictures! :wink:
so almost all the pictures are back and working :mrgreen:
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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Re: Ebike Project 72V UK "build thread"

Post by mike662 » Sep 14 2011 10:38pm

Nice build! I'm planning out my build for a 20S lipo bike using 4S 20C turnigy hard case lipo packs. I was just wondering how you found the quality of the battery medics from eBay to be? I am thinking about getting some myself. Although, can you get away using only 1 battery medic to balance one battery at a time every ten cycles or so?

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Sep 15 2011 6:29am

Battery medics are same quality as hk ones.
If you are thinking of using one battery medic to balance that will take 4 times longer than using 4...
How come you are using 4s packs??
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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Re: Ebike Project 72V UK "build thread"

Post by mike662 » Sep 20 2011 12:13am

rui_fujino wrote:Battery medics are same quality as hk ones.
If you are thinking of using one battery medic to balance that will take 4 times longer than using 4...
How come you are using 4s packs??
Thanks for the reply! I'm using the 4s packs as they are the cheapest quality lipo around and they are hardcased for extra protection. I would also like to get 20s for a nice 74V nominal battery pack, so I either need 5s or 4s packs and the 4s are cheaper.

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Sep 23 2011 6:20am

Its been couple weeks without any updates but here is what's been happening!
I received my 83V 5A charger for bulk charging.
I got my master battery switch (max 100A)
Also I'm back in UK with my bike!

Upcoming!
• Photos of bike with upgrades!
•Photos of charger/battery
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Sep 25 2011 7:46pm

Here is the pic of my BMSbattery charger.
IMG-20110925-00235.jpg
BMSBattery charger (600w, 83.0v)
Its 83.0V,5A, 600w bulk charger (UK input double pole connector output). I told them to add opposite side of double pin 75amp connector and they did it for free!
It came in 12days after I made my payment so I'm very pleased!
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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Re: Ebike Project 72V UK "build thread"

Post by mfosker » Sep 26 2011 3:41am

Are your battery medics and charger working well together? How long did it take for the battery medics to arrive from eBay?

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Re: Ebike Project 72V UK "build thread"

Post by theRealFury » Sep 26 2011 8:26am

Hello Rui,

Nice looking build. I have a quick question, have you loaded the flaconEV triangle battery bag with your 8 lipo bricks yet and if so, how did they fit in the bag? I currently have a powerinmotion triangle bag but its small and only just fits 4x bricks in it so im looking for something a bit bigger.
Fury

current bike

GT frame dual disk - Crystalyte HS3540- Rear (1600 miles of running) - 12s2P 10AH lipo.
Lyen 12FET Extreme MKII controller (awesome controller) - CA-DP.

Top speed - 32MPH
http://www.flickr.com/photos/63335907@N ... 869504840/ (New build pics now added)

Post licensed under the Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 License

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Sep 26 2011 8:34am

I had problem with HK shipping battery to me so they have been delayed. But the good news is that my battery is already in my country so I'll get them in next few days or even today!
As soon as I get the battery I'll get back to you guys about how it fits and how I charge with pictures!

Edit: my battery medic arrived in 6days
Last edited by rui_fujino on Sep 26 2011 9:41am, edited 1 time in total.
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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Re: Ebike Project 72V UK "build thread"

Post by theRealFury » Sep 26 2011 9:22am

rui_fujino wrote:I had problem with HK shipping battery to me so they have been delayed. But the good news is that my battery is already in my country so I'll get them in next few days or even today!
As soon as I get the battery I'll get back to you guys about how it fits and how I charge with pictures!
Nice one thanks :) Looking foreward to the updates.
Fury

current bike

GT frame dual disk - Crystalyte HS3540- Rear (1600 miles of running) - 12s2P 10AH lipo.
Lyen 12FET Extreme MKII controller (awesome controller) - CA-DP.

Top speed - 32MPH
http://www.flickr.com/photos/63335907@N ... 869504840/ (New build pics now added)

Post licensed under the Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 License

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Sep 28 2011 7:41pm

Finally! My battery has arrived this morning after 3weeks of waiting :D. I have tested all the batteries and so far all of them are between 3.85~3.87v and happy with it :).
IMG-20110928-00237.jpg
Here is my 5s 5000mah X8
Also, since I havnt really shown any of my bike pics I've taken some with my battery fitted into the falconEV triangle bag ;) (I have perfect space and more for my power switch to fit in :D)
IMG-20110928-00239.jpg
All 8 batteries fitted with ease! I can add more protection from the shock!
Last pic is my bike after upgrading!
IMG-20110928-00238.jpg
80% done!
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

theRealFury   10 kW

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Re: Ebike Project 72V UK "build thread"

Post by theRealFury » Sep 29 2011 2:44am

Nice looking setup there Rui,

Thanks for the pics of the Triangle bag and batteries... Just added a FalconEV triangle bag to my shopping list :) Good luck finishing the build off.
Fury

current bike

GT frame dual disk - Crystalyte HS3540- Rear (1600 miles of running) - 12s2P 10AH lipo.
Lyen 12FET Extreme MKII controller (awesome controller) - CA-DP.

Top speed - 32MPH
http://www.flickr.com/photos/63335907@N ... 869504840/ (New build pics now added)

Post licensed under the Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 License

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Sep 29 2011 8:11pm

Okay, today I finished all the wiring and cleared my mind to do important stuff like waterproofing, checking connections, checking +/- on battery etc...

Then I decided to charge my battery for tmr so I connected all up with battery medics and pluged into BMSbattery 600w bulk charger...and guess what...charger was broken and no sign of life...I've opened it up and I see cooling fan broken(plastic parts are snapped) and most of the heat sink screws are so loose...(Power indicator light won't even come on...) :'(

Anyway, I've made complaint and hopefully theyl send me new one!
Here is pic of the day....
IMG-20110929-00247.jpg
All connected but charger had to ruin my day...
IMG-20110929-00250.jpg
Battery medic's readings (all balanced)
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Oct 11 2011 9:26am

Okay, its been sometime and just to update what's going on.

At the moment I'm waiting for new BMSBattery charger(600w) because they came broken, I had to pay $24 for shipping fee....but after all its not too bad, I get new one while I don't need to send back the old one.

I am also fixing problem with lyen controller and motor...controller is little dead...

Mean while, I've been upgrading my bike so here is my new rock shox front fork!
Rebound, preload and lockout adjustment.
IMG-20111009-00280.jpg
Upgraded front fork!
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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Re: Ebike Project 72V UK "build thread"

Post by mfosker » Oct 11 2011 10:57am

It's good to know that BMSBattery are quick to respond and replace faulty items. In my case my battery charger, etc arrived OK and working but good to know all the same....

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Oct 11 2011 11:07am

mfosker wrote:It's good to know that BMSBattery are quick to respond and replace faulty items. In my case my battery charger, etc arrived OK and working but good to know all the same....
well i did had to email them couple time to let them know the situation and to prove how its not working,...
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Oct 15 2011 3:59pm

New lipo charger from bmsbattery and controller are on its way! As well as that, I have made couple more upgrades to my bike!
1, New front wheel with shimano disc hub!
IMG-20111011-00285.jpg
Disc hub front wheel
2, Manitou Swinger 3 way upgraded from 165mm spring to 190mm air!. Has SPV, rebound adjustment. So much lighter and more travel!!
IMG-20111015-00309.jpg
New rear air shock, Manitou swinger 3way
Edit: air shock makes sooooo much difference! Unbelievable:D
Last edited by rui_fujino on Oct 26 2011 9:19am, edited 1 time in total.
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Oct 21 2011 4:32pm

Quick update! I got my 2nd 12fet lyen controller today! Which means I can now plug that into my old battery set (54v hot) nd get going while bms charger is on its way! Once bmscharger arrives, I can run my 84v hot lipo! :D
Mean while, I'm thinking of getting Avid BB7 (2011) disc brake with cleansweep discs!
Oh, and air shock makes a MASSIVE difference on road! Its amazing! Never going bk to coil again!!
IMG-20111022-00317.jpg
lyen 12fet extreme mod controller
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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RichiePA   10 W

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Re: Ebike Project 72V UK "build thread"

Post by RichiePA » Oct 23 2011 12:31pm

Hey nice build, I'm building a similar spec bike myself and I'm focusing my attention on finding the best charging method at the moment so I'm keen to hear how your BMS charger works out although sounds like the first unit they sent was a bit poo.

Are you going to have andy protection inside the battery bag at the point where the shock rubs, LiPos are really easy to damage and it looks like you only have padding on the sides?
Giant DH Team, Crystalyte HT35 rear hub, Crystalyte 72V 45Amp controller,
Build thread here

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rui_fujino   1 kW

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Re: Ebike Project 72V UK "build thread"

Post by rui_fujino » Oct 23 2011 1:13pm

RichiePA wrote:Hey nice build, I'm building a similar spec bike myself and I'm focusing my attention on finding the best charging method at the moment so I'm keen to hear how your BMS charger works out although sounds like the first unit they sent was a bit poo.

Are you going to have andy protection inside the battery bag at the point where the shock rubs, LiPos are really easy to damage and it looks like you only have padding on the sides?
these Falcon EV bags has very thick layer (5mm) hard plastic so they wont be any problem. plus if anything, i can flip the valve of the shock to opposite side so i wont have any issue with them...tho if i do that, i wont be able to pump the shock easily...
BMS has already dispatched the item so hopefully i'll get it within next 2 -3 weeks :wink:
what's your setup like?
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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RichiePA   10 W

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Re: Ebike Project 72V UK "build thread"

Post by RichiePA » Oct 23 2011 6:03pm

rui_fujino wrote: what's your setup like?
The bike it's self is coming on nicely, I started with a big chunky downhill bike as I knew the bike would end up being big and chunky anyways, its not finished yet tho I'm giving myself a bit of time to ride the bike before I finish it off completely. Hopefully this means I can iron out the bugs now rather than finish it and then start changing stuff as I realise it doesn't quite work like I expected. link to my build thread is in my signature.

for the time being I'm running on 1/3rd of the total battery pack just 4 5S 5Ahr packs in series untill I can make a battery box to fit all 12(4s3p). So as you can imagine there's a lot og gaffa tape holding everything in place right now but it seems ok.

As I said its the charging which is my biggest issue at the moment. I only have a turningy accucel 6 50W charger so this take 90-120min to charge just one individual pack. bulk charging sounds like its the way forward but there seems to be a whole load of different ways you can charge bigger lipo packs so the more feedback I can get the better. the last thing I want to do is spend hundreds of £ and then find I could have done it better or cheaper. I'm really tempted by the Hyperion duo3 1000W balancing lipo chager but its £200+ and I'd need a pretty expensive power supply to run it.

How much was your charger if you dont mind me asking?
Giant DH Team, Crystalyte HT35 rear hub, Crystalyte 72V 45Amp controller,
Build thread here

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