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

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Jan 21 2012 7:20pm

I got my extension wires so I thought I'll put on some new tire for the new HS3540!
It's Specialized Crossroads Armadillo,which are known to have special type of anti-puncture kevlar and has been tested as one of the strongest tire!

I got two of these plus tubes for £44!
IMG-20120121-00488.jpg
The treads on the tire
IMG-20120121-00492.jpg
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 HS3540 UK "build thread"

Post by rui_fujino » Jan 27 2012 4:47pm

I've programmed lyen controller to the following settings. i'll take it for spin in next few days and adjust it and I want to find out how fast can 30%, 40%, 50% can do.
also if anyone spots anything odd about my settings please let me know before I blow up something :twisted:
keywinLab.JPG
Lyen Keywin E-bike Lab
keywinLab.JPG (60.2 KiB) Viewed 2438 times
Last edited by rui_fujino on Feb 02 2012 11:42pm, 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 HS3540 UK "build thread"

Post by electr0n » Jan 27 2012 11:17pm

That's a nice setup you got there. I like the break light too. How is the performance compared with your other builds? What voltage and amperage are you running?

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Jan 28 2012 11:45am

electr0n wrote:That's a nice setup you got there. I like the break light too. How is the performance compared with your other builds? What voltage and amperage are you running?
So far I've only done less then 10miles so I can't say how its going but compared to my last build its much smoother and reliable.
I'm running 20s 83v hot 10ah but I havnt sorted CA settings so I'll need to do that soon
Ps here is a picture of my first ever KFF
IMG-20120128-00497.jpg
KFF
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 HS3540 UK "build thread"

Post by rui_fujino » Jan 28 2012 5:04pm

I've fixed my fried connector and took it for a ride. Top speed I've got today is 44.5mph(72km/h) which is my high speed record on flat!
I'll measure the weight of my bike tmr and see his much it weighs.
Also I've smelt something burning but I didn't find any...does anyone know what it could be?
More pictures of my bike coming up soon!
IMG-20120128-00498.jpg
Last edited by rui_fujino on Jan 28 2012 7:45pm, 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 HS3540 UK "build thread"

Post by rebelpilot » Jan 28 2012 5:19pm

rui_fujino wrote: Also I've smelt something burning but I didn't find any...does anyone know what it could be?
My HS3540 smelled burnt for the first couple of weeks of 18S Lipo use, with the CA set for 30A. Usual trip data shows an average speed of 35-50 kmh, the max speed is always 72 kmh. 782 total km on this motor so far.

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by Trackman417 » Jan 31 2012 7:53am

One question I have is, why does the motor smell burnt? Is it the amount of power you are pushing though the motor? Good job with the kit! I'm jealous of your progress =D
K2 Sidewinder
H4065 36 mph
20s2p 10aH lipo battery pack
If it didn't kill you, it just built your character.
You know your bike is powerful when even you, the builder, can't control it.
Customer 00001 at our very own Bigmooses online store http://mtg-technologies.com/zencart/ Great guy, great products.

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Jan 31 2012 2:47pm

Trackman417 wrote:One question I have is, why does the motor smell burnt? Is it the amount of power you are pushing though the motor? Good job with the kit! I'm jealous of your progress =D
I think its because new motor has coating on coil which makes burnt smell when it gets hot. Even if outer cover doesn't get hot or warm coil still can get hot for a half minute when you put high current through.

Anyway, so today I went for another 3miles commute and I've realised I couldn't go any faster due to low voltage. CA shows 71v at half throttle...so I've decided to charge them for the first time! With my BMSBattery charger :wink:

Here are some pics of charging process :D
IMG-20120131-00500.jpg
Here is BMS Battery bulk charger (83v 5A)
IMG-20120131-00501.jpg
Battery charging with battery medics to balance charge
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 HS3540 UK "build thread"

Post by Trackman417 » Jan 31 2012 7:46pm

Alright so you don't think it's just the motor about to melt down.... WELL THAT'S AWESOME! Like the ideas you cone with. Hehe I might steal a few :twisted:
K2 Sidewinder
H4065 36 mph
20s2p 10aH lipo battery pack
If it didn't kill you, it just built your character.
You know your bike is powerful when even you, the builder, can't control it.
Customer 00001 at our very own Bigmooses online store http://mtg-technologies.com/zencart/ Great guy, great products.

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Jan 31 2012 8:00pm

Trackman417 wrote:Alright so you don't think it's just the motor about to melt down.... WELL THAT'S AWESOME! Like the ideas you cone with. Hehe I might steal a few :twisted:
well, i didnt run high amp on the motor "yet" so it shouldnt melt down :P

I also took a picture of battery setup so that you can see whats in the bag :wink:
I think its pretty neat 8)
IMG-20120131-00502.jpg
here is my batteries inside the bag.
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 HS3540 UK "build thread"

Post by rui_fujino » Feb 03 2012 9:00pm

at the moment i'm trying to get the Rshunt value correct for the CA but I dont have watt meter... :oops:
does anyone here know the Rshunt for the 12 fet lyen controller?? Lyen has told me its 2...but I'm sensing its not correct.
if anyone can help it'll be great! :wink:
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 HS3540 UK "build thread"

Post by rui_fujino » Feb 05 2012 3:07pm

I went out for a ride today and snow is so thick that I couldn't cycle at all...on top of that my controller got splashed by the front wheel despite the fact I got mud guard...I lost the power due to wet throttle so I had to cycle back home and dry the connectors.
But now I know that I need to waterproof the connectors :D
IMG-20120205-00509.jpg
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 HS3540 UK "build thread"

Post by hotrod » Feb 05 2012 3:34pm

hi, rshunt is set to 2.300mohm on 12fet lyen controller. yours should be around that figure hope this helps
10s lipo
rear conhis hubmotor upgraded to 12awg
Lyens 72v 12 fet controller
giant fss
7500miles

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Feb 05 2012 3:44pm

hotrod wrote:hi, rshunt is set to 2.300mohm on 12fet lyen controller. yours should be around that figure hope this helps
thanks alot! that sound about right. I'll change it tomorrow and see if it make sense :D
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 HS3540 UK "build thread"

Post by rui_fujino » Feb 06 2012 8:10pm

OMFG!!!!!!! :evil: :evil: :evil: :evil: My BMSBattery charger has broken AGAIN!!!!! (2nd time)
I only charged my battery once to fulll...and now I was going to charge and before I even start charging it makes buzzing noise and nothing else... :cry:
I have sent an email to BMSBattery..they better reply ASAP!
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 HS3540 UK "build thread"

Post by Scottyf » Feb 07 2012 5:35am

Sorry to hear about your BMS battery charger issue.
Its always the chance you take it buying from China at a hideously cheap price.

I personally have done the same from BMS but the 240w bulk charger. Which lets face it. Isn't that quick in the realm of bulk charging.
I hope mine works. But i've only paid £40 all in with the delivery. Which cost the same amount as the actual charger.

I hope you get yours sorted or fixed though. Nothing worse than having to slowly charge your packs...
Marin kentfield FS - Unassisted

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by Trackman417 » Feb 07 2012 7:59am

Sorry to hear about your troubles :( you should get American made enginuity:D http://epbuddy.com/index.php?main_page= ... cts_id=170. I'm getting this setup and now all you have to do is get a charging harness from icecube and you are set! Btw I just got that list yesterday and they have some good reviews. I just ordered mine yestarday and in an hour or two they sent me a tracking number. Supposed to be hear today or tomorrow :D GOOD STUFF! Anybody have anything good to say about epbuddy?
K2 Sidewinder
H4065 36 mph
20s2p 10aH lipo battery pack
If it didn't kill you, it just built your character.
You know your bike is powerful when even you, the builder, can't control it.
Customer 00001 at our very own Bigmooses online store http://mtg-technologies.com/zencart/ Great guy, great products.

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by ohzee » Feb 07 2012 8:34am

EPBuddy is pretty awesome. He's local to me so I have even picked up packages before.. I ordered some wire last week and had it to my door
the next day.. I do live withing 10miles though so I am sort of cheating . My 306b had a weird issue where the fan failed to turn on so I was concerned
how warm it was getting. I took it over to his house he pulled out a new 306b and a battery to verify the fan worked.

So yea EPBUDDY is good stuff.

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by Trackman417 » Feb 07 2012 9:32am

And the best part, they are American! Are they based in Ohio? That's what it says on their website. So I'm guessing my package should be hear today or tomorrow:D
K2 Sidewinder
H4065 36 mph
20s2p 10aH lipo battery pack
If it didn't kill you, it just built your character.
You know your bike is powerful when even you, the builder, can't control it.
Customer 00001 at our very own Bigmooses online store http://mtg-technologies.com/zencart/ Great guy, great products.

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Feb 07 2012 9:45am

Thanks guys for the alternatives but again, those chargers are slow balance chargers and k won't be able to bulk charge unlike mean well or bmsbattery...
I've talked to Judy Liu from bmsbattery and he said I'll need to take a picture of the inside and if its broken for non-visible reasons then he can send me a new one for free!
Mean while I might buy icharger so slowly charge...
Any suggestions of charger I can use that are cheap off eBay?
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 HS3540 UK "build thread"

Post by Trackman417 » Feb 07 2012 9:51am

Ehhh slow? Lol 20 amps isn't fast enough? Haha geez you must be the fastest moving man in the world :shock:. Good luck with your charger:D
K2 Sidewinder
H4065 36 mph
20s2p 10aH lipo battery pack
If it didn't kill you, it just built your character.
You know your bike is powerful when even you, the builder, can't control it.
Customer 00001 at our very own Bigmooses online store http://mtg-technologies.com/zencart/ Great guy, great products.

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by Scottyf » Feb 07 2012 12:21pm

You can get lipo chargers from the UK.
A resonable priced 10amp (200w) charger from www.giantcod.com
will cost you about £40. But least that will charge your packs in a few hours. You will need a power supply though to run it.
Marin kentfield FS - Unassisted

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rui_fujino   1 kW

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Re: Ebike Project 72V HS3540 UK "build thread"

Post by rui_fujino » Feb 07 2012 6:48pm

Scottyf wrote:You can get lipo chargers from the UK.
A resonable priced 10amp (200w) charger from http://www.giantcod.com
will cost you about £40. But least that will charge your packs in a few hours. You will need a power supply though to run it.
Scottyf, thanks for the info but the web you tagged isn't working... :? also I am looking for plug and charge rather than those that requires power supply... :(
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 HS3540 UK "build thread"

Post by rui_fujino » Feb 08 2012 7:03pm

well. while im waiting for the bulk charger to fix its self...I've decided to get slow balance charger.
does anyone familiar with Dynam Supermate DC6 Double Power?
Image
I only got this cos it was cheap on ebay and i can charge 2x5s2p at the time!
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 HS3540 UK "build thread"

Post by rui_fujino » Feb 10 2012 9:36pm

Hi, Here is update! Since I have uploaded few things on the other threads I'll put them here.
they are my current handlebar situation! I think they are pretty neat :wink:
IMG-20120210-00542.jpg
FAS XC282 DH Handlebar:
CA-DP with Speedometer
Bicygnals Adaptor
3 way switch
Thumb throttle
Shimano EZ fire shifters
Custom LED lights
Cheap rear view mirror(to be upgraded)
IMG-20120210-00543.jpg
Took a long time to figure out the perfect ways to put 3way switch, throttle and shifter/brake all together while keeping them look neat! :wink:

Here is my whole bike in snow!
IMG-20120210-00545.jpg
Also update on the Charger.
I got the slow charger from ebay and It arrived today!
IMG-20120210-00539.jpg
I have charged half of all the packs but its going to take more time to charge the other half...can not wait to get my bulk charger back!
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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