mon-goose to MON-STER

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pendragon8000   1 MW

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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Mar 29 2013 12:10am

pendragon8000 wrote:test spin up with new wires and plugs etc... something strange happens :shock:

so it running in reverse.. HELP anyone? im guessing i can swap 2 halls and 2 phases?
or look at the software.. I'd like to ride it stock (software) though while testing.
ill have a search around to find the answere but if anyone wants to jump in and help me out I'd really apriciate it. cheers
tried switching 2 phases then 2 halls then 2 phases and 2 halls. switching 2 phases and 2 halls maded it spin in reverse. others made it vibrate with no movement.

Edit:
really quick replys from Lyen :)
Lyen Controller to Crystalyte motor wire color lining (no load current draw on HS3540 = around 1.55A unlaced at 48v tested on 8/10/2012):

Controller: Motor:
HALL:
Yellow Yellow
Green Blue
Blue Green

PHASE:
Yellow Blue
Green Green
Blue Yellow
SUCCESS! spins beautifully in the correct direction. must have missed the corect phase combo when i switched the halls (that i randomly got the right combo of when i cut the wires)

next step; battery harness / series plug
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pendragon8000   1 MW

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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Mar 29 2013 8:36am

thought Id better mount the controller so i can have it handy when getting other bits on there so...
lyen 18x4115et.JPG
lyen 18x4115et.JPG (47.6 KiB) Viewed 2888 times
I used a block of black nylon at the front end to screw counter sunk screws into.
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Re: mon-goose to MON-STER 6KW

Post by Hyena » Mar 31 2013 5:30am

how did you mount the thermostat ? You shouldn't have any extra wires leaving the motor, that's the whole reason I do them like that. You cut out of the hall wires and solder the thermostat in there in series.

As for your welding, well, it ain't going to win any beauty contests :P As long as it doesn't break on you at speed! If it's mainly for street use you should be right.

Oh and your kwh capacity goes off the nominal voltage (or closer) not the fully charged voltage x ah capacity.
So you'd be looking at around 900 whr. Still a respectable amount of most purposes.
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Re: mon-goose to MON-STER 6KW

Post by Trackman417 » Mar 31 2013 7:59am

pendragon8000 wrote:thought Id better mount the controller so i can have it handy when getting other bits on there so...
lyen 18x4115et.JPG
I used a block of black nylon at the front end to screw counter sunk screws into.
Wow :shock: Your bike is definitely starting to come together. I think I'm jealous. Everything is starting to look great. Have fun, hope all goes well from here.
Sorry I couldn't help with some of your answers of let you touch my infinite wisdom :wink: .
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pendragon8000   1 MW

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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Mar 31 2013 9:51am

Hyena wrote:how did you mount the thermostat ? You shouldn't have any extra wires leaving the motor, that's the whole reason I do them like that. You cut out of the hall wires and solder the thermostat in there in series.
the extra wire is from a ntc thermistor. I put the thermostat in there as you said, cutting the common positive hall wire.
Hyena wrote:As for your welding, well, it ain't going to win any beauty contests :P As long as it doesn't break on you at speed! If it's mainly for street use you should be right.
yeah im prety sure it will be fine. I still have to re-enforce the ends of the battery box with triangle brackets.
Hyena wrote:Oh and your kwh capacity goes off the nominal voltage (or closer) not the fully charged voltage x ah capacity.
So you'd be looking at around 900 whr. Still a respectable amount of most purposes.
thanks i didn't know that, I guess that would make sense.

So here's my progress...
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Trackman417 wrote:Wow :shock: Your bike is definitely starting to come together. I think I'm jealous. Everything is starting to look great. Have fun, hope all goes well from here.
Sorry I couldn't help with some of your answers of let you touch my infinite wisdom :wink: .
thanks. yeah its comming along. i hope i get it rideable tomorow. i need another torque arm and then i can get around without the cycle analyst at least.
happy and tired...

I think i found the diode in the controller i need to swap for 10k R, it looks to be connected to the blue wire on ca direct plug... not sure whats going on there.
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Mar 31 2013 7:08pm

throttle diode.jpg
lyen 18x4115fet
throttle diode.jpg (34.16 KiB) Viewed 2834 times
has anyone played with this? its not a huge priority but i have the controller open ready to change the diode if thats the problem. i have not got a responce from Lyen on this one. I'm guessing he's busy or doesnt know. i will try connecting a throttle to the ca and the controller and see if i can come up with something.

my multimeter says 25K ohm from ca direct plug throttle wire to the circled diode.

any help would be much apriciated.
Edit
Lyen DID reply. I just missed it somehow. He is most helpfull
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 01 2013 7:07am

put a 10k R in place of the diode but it seemed a bit high because even with 5v throttle input from the CA it wasn't spinning up all that fast. so i put a 5k in there. still seems a bit restrictive but i cant be certain because i set the speed limit of the Lyen controller to 80%
anyway i went for a cruse and limited to 500watt first then when i decided it was safeish i put it upto 1KW. i was getting a top speed of 40kph at 1kw.
IMG_20130401_164349.jpg
prety unexciting but may be of use to someone in the future.

so heres how it looks atm. needs another torque arm and the battery box isnt really big enough for battery monitors as well so ill set up an external compartment thing with switches or something. and yeah its heavy as buggery. (thats heavy)
also needs some attention in the steer tube bearings (needs to be tightend up)
IMG_20130401_213515.jpg
IMG_20130401_213515.jpg (48.8 KiB) Viewed 2804 times
need to play with phase angle aswell.

anyway. i spent most of easter on this trying to get it done, at least i got to ride it easter monday night. still need quite a few hrs on it for it to be finished.
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 02 2013 8:09am

Ok after a few PM's with Kepler about the CA and the Lyen controller I reread my email from Lyen that i couldn't find b4 cos i was so tired... and he said 1K ohm in place of diode not 10k agh.. so i had just bought some 1k for the precharge resistor led indicator, and so i put it in and runns SWEEEET! i couldnt resist switching it up to 1.5 kw and it felt so smooth and like it wasnt trying to hard on take off. i do have the phase angle at 120 deg i think so that may explain the power consumption being a little high, Ill switch that to auto as per Keplers advice.

anyway, finaly got to have a ride with the throttle working properly so now its onto:
- strengthening the frame a little
- tighten up the head tube / steer tube bearings
- make another torque arm.

then i can put some proper lights on there and my 24v car/truck horn.
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Re: mon-goose to MON-STER 6KW

Post by biky » Apr 02 2013 3:10pm

Wow excellent work guys

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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 03 2013 7:48am

biky wrote:Wow excellent work guys
thanks Biky :) .. plural ok that goes out to all the other ES crew that helped me out I guess.
heres tonights effort. much nicer welds, just for your Jay ;)
botom triangle bracket.JPG
botom triangle bracket.JPG (36.24 KiB) Viewed 2742 times
close up welds.JPG
close up welds.JPG (34.8 KiB) Viewed 2742 times
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Re: mon-goose to MON-STER 6KW

Post by Floont » Apr 03 2013 2:25pm

pendragon8000 wrote:Ok after a few PM's with Kepler about the CA and the Lyen controller I reread my email from Lyen that i couldn't find b4 cos i was so tired... and he said 1K ohm in place of diode not 10k agh.. so i had just bought some 1k for the precharge resistor led indicator, and so i put it in and runns SWEEEET! i couldnt resist switching it up to 1.5 kw and it felt so smooth and like it wasnt trying to hard on take off...
What is gained by replacing this diode with a 1K Ohm ??? watt resistor? Increased acceleration at a dead stand-still or what?

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mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 03 2013 8:53pm

The way the cycle analyst v3 connects to the controller won't work with a diode. So for this controller a 1k ohm R is required. Kepler and myself agreed that theoretically a link could be used instead but apparently that is not suited to the Lyen 4115x18 controller.
The CA v3's throttle output min and Max are set so the throttle varys in the effective range only so if u need it to be up toward 5v to get full throttle (because of the 1k R)I can do that. At this stage 4.2 volts seems to give me full throttle. But this may change when I reprogram the controller via USB PC connect.
This resistor
Image
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 05 2013 9:59pm

lastnight i reprogramed the controller as such:
lyen software1.JPG
lyen software1.JPG (43.89 KiB) Viewed 2662 times
thismorning i put a new chain on and linked it with a 2 piece linker similar to this
Image

Ok today i'll be; adding the triangulation bracket to the front of the battery box, drilling and taping 5mm thread holes in steer tube to tighten up the tiny bit of slack in the bearing housing, put a latch on the batery box lid (although the rubber strap is doing a great job).
then paint with the "epoxy gloss enamel" (anti corosive top coat no primer required)
then i have a SUPRISZE for you all :) hint:
Image
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Re: mon-goose to MON-STER 6KW

Post by jkbrigman » Apr 06 2013 12:53pm

Pendragon - thank you for the extreme detail. I'm aiming to upgrade to a similar controller and will probably need to perform the same resistor-substitution process.
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 06 2013 7:29pm

jkbrigman wrote:Pendragon - thank you for the extreme detail. I'm aiming to upgrade to a similar controller and will probably need to perform the same resistor-substitution process.
no worries. Lyen would probly swap it for you if you let him know you want to run a ca v3. thats why i had to do the diode to 1k R swap.
painted black.JPG
painted black.JPG (66.73 KiB) Viewed 2626 times
there it is with mimial wire and just straight up black enamel paint.
when i was wire wheeling off old stickers and paint i accidently got the brake and gear cables cought up in there and they are now mangled... so ill have to replace them i think front derailer cable is ok. bummer cos the rear derailer cable was new .. sholdn't cost much. anyway i have 1 other thing to do b4 todays trail ride ;)
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 06 2013 8:34pm

monster2.JPG
monster2.JPG (68.7 KiB) Viewed 2623 times
monster1.JPG
monster1.JPG (72.1 KiB) Viewed 2623 times
;
It looks photo shoped its so fresh and shiny :D 8)
still have to put the controller back on and plug things in.
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Re: mon-goose to MON-STER 6KW

Post by mushymelon » Apr 06 2013 8:48pm

Nice work man almost there.

I hope you don't mind but I darkened out the rear end.
Just a suggestion.

Mushy
painted%20black1.jpg
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Last edited by mushymelon on Apr 06 2013 9:11pm, edited 1 time in total.

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Re: mon-goose to MON-STER 6KW

Post by Trackman417 » Apr 06 2013 8:57pm

wow :shock:
Not bad for your first time welding man!!!! :D . Everything being the same color and the monster energy stickers just bring the bike together. How hard was welding the aluminum for your first time?
I am really impressed with the series block you made! It's so idiot proof, I wish I thought of something like that for my bike. However, it is just a frame with a bag in it. Nothing too sturdy to do that with.
Yeah I agree Mr.Mushymelon about the motor. It doesn't really match the rest of the bike. But no offense in any way possible :P
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Re: mon-goose to MON-STER 6KW

Post by dimpirate » Apr 06 2013 9:01pm

Nice! Looks badass! 8)

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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 07 2013 2:42am

Mushymelon, thanks for the photo shop I think I may go there with the pain on the hub. Maby just the side plates? The spoke flange may be to much of apita to paint.
Thanks trackman and dimpirate.
More photos soon and a couple vids ill have to edit together. I think a new avitar is coming ;)

Also thanks to Hyena, Kepler, Lyen, John (from stealth), Rix, other es members for welding advice.
Btw its STEEL not aluminum. And I got better as I went with the arc welding.
PS
Its my birthday and my gf got me a camzilla phone mount for me bike . I used it for the video I'll upload later. Its choice :)
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 07 2013 3:42am

monster and rock face.JPG
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eagle trail 2 ebikes.JPG
eagle trail 2 ebikes.JPG (113.04 KiB) Viewed 2601 times
nice view 2 ebikes.JPG
nice view 2 ebikes.JPG (85.93 KiB) Viewed 2601 times
from todays ride with my GF. she strugled a bit the poor thing had to walk the bike thrtough some parts, it was her first off road bike sesh so i tried to be patient. hopefully she will get her skills up and we can blitz around together :)
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 07 2013 6:03am

test ride

eagle mtb park. followed by gf on scott spark with camzilla on handle bar.
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Re: mon-goose to MON-STER 6KW

Post by Hyena » Apr 07 2013 6:19am

Heh the old monster decals hey. I looked at some of those a few weeks ago when trying to make my cut and shut specialized bike look more factory but they didnt suit the bike. I've seen alot of pit bikes and the like with them and they suit well.

The bike has turned out pretty well. Are you going to leave it at that or do more work / revisions ?
If starting over and you want the advice of someone who's not particualrly qualified to give it :P I'd recommend replacing the whole downtube section and headtube with a new piece/box and then just weld on the bottom bracket and what ever part of the top bar / seat post support is suitable to keep. In your case it would be easy. Eg like this:
monster.JPG
monster.JPG (92.04 KiB) Viewed 2578 times

This is what I'll be doing and it's how timma2500 does his brilliant creations too. They're thicker aluminium but same deal essentially.
Oh and +1 for the black painted hub.
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Re: mon-goose to MON-STER 6KW

Post by pendragon8000 » Apr 07 2013 7:26am

Hyena wrote:Heh the old monster decals hey. I looked at some of those a few weeks ago when trying to make my cut and shut specialized bike look more factory but they didnt suit the bike. I've seen alot of pit bikes and the like with them and they suit well.

The bike has turned out pretty well. Are you going to leave it at that or do more work / revisions ?
If starting over and you want the advice of someone who's not particualrly qualified to give it :P I'd recommend replacing the whole downtube section and headtube with a new piece/box and then just weld on the bottom bracket and what ever part of the top bar / seat post support is suitable to keep. In your case it would be easy. Eg like this:
monster.JPG

This is what I'll be doing and it's how timma2500 does his brilliant creations too. They're thicker aluminium but same deal essentially.
Oh and +1 for the black painted hub.
thanks for the advice...
well what I AM going to do is add a second clamping torque arm so i can pump the for told 6kw through the HT3525.
and add the 24v horn thats going to be taped off one 6s pack, and add the high wattage lights i made.
i was thinking about adding a housing around the frame where you added frame in you edited version, to contain the 240v plug pack(s) come dc-dc converters. But yeah thanks for the insperation to follow timma2500's desighn, that photoshoped version looks prety sik. and yeah agh more work to paint the hub and rear arm.

any votes / sugestions on how to do it , regarding spokes? just do the lot and mask the rim/tyre?
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Re: mon-goose to MON-STER 6KW

Post by mushymelon » Apr 07 2013 12:46pm

pendragon8000 wrote:
Hyena wrote:Heh the old monster decals hey. I looked at some of those a few weeks ago when trying to make my cut and shut specialized bike look more factory but they didnt suit the bike. I've seen alot of pit bikes and the like with them and they suit well.

The bike has turned out pretty well. Are you going to leave it at that or do more work / revisions ?
If starting over and you want the advice of someone who's not particualrly qualified to give it :P I'd recommend replacing the whole downtube section and headtube with a new piece/box and then just weld on the bottom bracket and what ever part of the top bar / seat post support is suitable to keep. In your case it would be easy. Eg like this:
monster.JPG

This is what I'll be doing and it's how timma2500 does his brilliant creations too. They're thicker aluminium but same deal essentially.
Oh and +1 for the black painted hub.
thanks for the advice...
well what I AM going to do is add a second clamping torque arm so i can pump the for told 6kw through the HT3525.
and add the 24v horn thats going to be taped off one 6s pack, and add the high wattage lights i made.
i was thinking about adding a housing around the frame where you added frame in you edited version, to contain the 240v plug pack(s) come dc-dc converters. But yeah thanks for the insperation to follow timma2500's desighn, that photoshoped version looks prety sik. and yeah agh more work to paint the hub and rear arm.

any votes / sugestions on how to do it , regarding spokes? just do the lot and mask the rim/tyre?
I say order a set of stainless spokes and shelf them for now.
$20 black or stainless.

Heres a link, many spokes to choose from, decent pricing as well the page takes a min to load scroll down to the bottom.

http://electricrider.com/crystalyte/parts.htm

Have fun riding then when your ready remove the spokes take the motor out do it right.

But for now just go ride the thing.

Mushy

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