Axel's Giant DH Comp

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GCinDC   10 GW

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Axel's Giant DH Comp

Post by GCinDC » Apr 14 2014 1:05pm

2002 Giant DH Comp, before:
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After:
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Specs:
- kiwi's DH Comp Dropout Adapter
- Adaptto Mini-E Controller + Display (no BMS yet) - 6kW max
- 20s2p Turnigy 20C lipo (10Ah) in custom frame/bag
- vented hs3580 in 19" x 1.85" MC wheel with Shinko 244 tire
- Half Twist throttle
- 7spd 11T-32?T freewheel, shifter flipped and installed on left grip

Little testing vid before upping the OVS timing to increase acceleration:


These pics are from my thread here but will soon get buried, so am creating a thread for Axel.

Build Pics

Cooked insulation on hs3540 phase wires, pre-upgrade:
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Upgraded Phase wires:
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Custom Controller Connections (Charge + Precharge)
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finished:
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throttle wiring:
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longer bolts were required to mount display around fat part of bar:
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pack container made of 3-5/8" galvanized steel stud, with all edges covered w/ gorrilla tape:
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Custom Cordura bag:
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Charging:
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now's it up to Axel to post pics and vids! :twisted:
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 14 2014 1:14pm

ps Axel, i meant to tell you - i don't like those DB25 metal edges against the lipos. you need to put something in between...
Image
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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Metallover   10 kW

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Re: Axel's Giant DH Comp

Post by Metallover » Apr 14 2014 1:16pm

Thank you for posting this!! Great info here! :D
Add your bike to the Unofficial E-Bike Garage! - http://spreadsheets2.google.com/ccc?key ... OWcg&hl=en
My Build - Vector Frame, 20s 25Ah LiPo, Max-E, Cromotor - 10.89HP on the Dyno

crezzy2k1   1 W

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Re: Axel's Giant DH Comp

Post by crezzy2k1 » Apr 14 2014 2:11pm

What a fantastic build!. Greg you have some awesome Skillz :D
2004 Giant DH Comp: 24s4p, HS3540, Lyen 18fet
2010 Giant Boulder SE: 36V 20AH, MAC 7t, Lyen 12fet

drew12345   10 kW

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Re: Axel's Giant DH Comp

Post by drew12345 » Apr 14 2014 2:23pm

Nice clean build!

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Axel   100 mW

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Location: Meudon, France

Re: Axel's Giant DH Comp

Post by Axel » Apr 14 2014 3:06pm

Yes very clean bike !
I am thinking to change the front tire and I saw this new one:
http://www.csttires.com/int/bike/hybrid ... ach-c1815/
anybody test it already ?
Or any suggestion ?
A

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beast775   100 kW

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Re: Axel's Giant DH Comp

Post by beast775 » Apr 14 2014 3:49pm

Gcindc,thought maybe you were updating youre nickname to axel :lol: . really like the cordura material and it looks slick! well done...
2 FINGER SALUTE TO ESSO.no buying gasoline for 7 years now.
I spent all my money on bicycles women and beer the rest i just wasted.

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 17 2014 2:08pm

axel, how's the temp of the controller in the batt box?

have you figured out how the system protects against overheating?

in the top right, you see the motor temperature, and only when it gets near 300F will it start to slow you down (and show bars rising on the bottom right).

if the motor is cool, or not too hot, and you go up a VERY steep hill or something, the controller may get very hot and show bars rising on the bottom right. so if you see the bars, and the motor temp is below 300, you know it's the controller getting hot.

make sense?
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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Axel   100 mW

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Re: Axel's Giant DH Comp

Post by Axel » Apr 19 2014 9:23pm

The temp of the controller looks good, but …. I haven't been able to test the bike more than the first day :(
I was not home.
I came back this afternoon,and I am traveling tomorrow to Boston for 2 days.
I just ride the bike this afternoon in Bethesda to go quickly buy something, with a lot of fun !
I hope to be here in the week and really test it.
I'll check the bars and the motor temp.

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Axel   100 mW

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Re: Axel's Giant DH Comp

Post by Axel » Apr 19 2014 9:28pm

Oh ! I forgot !
I bought a Holy Roller.
It was in front door today, looks nice :D

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Axel   100 mW

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Re: Axel's Giant DH Comp

Post by Axel » Apr 22 2014 6:33pm

The good news and the bad news !!

The good news: :D :D
I came back yesterday night home after a trip for my work.
So I decided to set the new tire.
Done, so I went for a ride to test it.
I had 28% left.

The bad news: :shock:
I turn the throttle but the bike did not really started I usual.
The e-mini shows "low battery", it was still 28%, but 45V !
The batteries are dead ! :( :(
I left the bike Saturday with 75V and the batteries were unplugged.

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 22 2014 6:44pm

du calm. this is a time to be rational.

forget about the minie for a second. use a multimeter and tell me the voltage of the pack, not connected to the bike. measure across big red and big black (not precharge)..

gimme the number.
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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Axel   100 mW

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Re: Axel's Giant DH Comp

Post by Axel » Apr 22 2014 7:22pm

55.5 V :(
dead !

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dan974   1 kW

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Re: Axel's Giant DH Comp

Post by dan974 » Apr 25 2014 2:00am

I found that if you need a new pack and ther's a US warehouse , no test right now...
15Ah 8S !!
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http://www.chinahobbyline.com/ProductShow.asp?id=2534
http://www.chinahobbyline.com/ProductShow.asp?id=2529

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Axel   100 mW

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Re: Axel's Giant DH Comp

Post by Axel » Apr 25 2014 8:23am

Awesome ! but 2390g !!
they are apparently out of stock, thanks to my wallet !! $300 each :roll:

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 25 2014 9:11am

hey axel, to connect plug & play to the BMS (whenever it arrives), i really think you should buy 10 x 4s packs (or the 5ah ones) for 20s2p or 4 x 8s zippys (w/ 2 x 4s jst-xh connectors) + 2 x 4s packs for 20s2p and 5 of these:
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(unless you think you'll try to go 3p or more but you can always get the parallel balance connectors later, like these)

if you're dying to get on the bike now, and i know you are, i can loan you 6x6s packs for 18s2p, and just slightly lower top speed...

let's talk this afternoon...
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 25 2014 9:29am

And just for the record (and the benefit of the community), if i understand correctly, you plugged the battery into the charge port (charge GND and main + leads) and rode the bike. You noticed that it had less power than normal. (I didn't know it was possible). I'm very curious what the display showed at this time; did it show negative amps, as if charging?

and you must have drained the pack to 55V (2.75V/cell) during this ride, right? because you said you left the battery disconnected from the controller before your trip, right?

no shame in it! just another lesson learned! :wink:
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

dnmun   100 GW

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Re: Axel's Giant DH Comp

Post by dnmun » Apr 25 2014 9:57am

why doesn't the BMS shut down the controller at the 2.7V level? there must be some sorta voltmeter on the display that reads out the pack voltage too so there is time to shut down when it gets to the 62V level or did this just drain down over the weekend while the controller was left on? it should still shut off at LVC even if unattended.

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 25 2014 10:13am

dnmun wrote:why doesn't the BMS shut down the controller at the 2.7V level?
no BMS yet.

but under main menu > BMS Setup there is a Low Voltage Discharge Cutoff. I wonder what it's set to! Axel, can you check?

I assumed it didn't think it was discharging because it was attached to charge port, but don't know. Good question..
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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Re: Axel's Giant DH Comp

Post by dnmun » Apr 25 2014 10:36am

ok, charger drained it down through the charging port while the charger was off. that is not much current. about 56V/5k6R or about 10 mA so it should not damage it discharging at that rate. we just don't know if one of the cells got lower than 2.7 while it was in use.

hoping the voltmeter is inaccurate too.

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 25 2014 10:52am

hey dennis, it wasn't connected to the charger..

here's a pic w/ serialized batt connectors plugged into discharge leads. axel had disconnected these and then when he reconnected, he plugged in the single + lead and attached the precharge + and GND connectors to the charge leads shown at bottom:
Image
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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Re: Axel's Giant DH Comp

Post by dnmun » Apr 25 2014 10:58am

so it could be draining through the precharge resistor.

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Axel   100 mW

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Re: Axel's Giant DH Comp

Post by Axel » Apr 25 2014 11:06am

exactly, and I did a very short ride close to my house
It was so short that I did not look well at the display, just remember 28%
I unplugged every thing and 3 days after, I set-up the new tire, plugged the batteries, saw 28%, but when I used the throttle, I had no power !
But Greg when I rode it with batteries into the charge port, it has not less power, it has more power at the beginning (in eco mode) and it was cutting the power for millisecond. I bought at this time that I did a wrong set-up in the mini-E

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Re: Axel's Giant DH Comp

Post by dnmun » Apr 25 2014 11:08am

ok, that's good. it means the BMS was functional and it shut off when throttle applied.

so the problem is just getting the charger to charge it?

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GCinDC   10 GW

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Re: Axel's Giant DH Comp

Post by GCinDC » Apr 25 2014 11:19am

hmm, sounds odd. i better stop by and have a look, unless you want to chuck it in the van and come over? i'm supposed to go to baseball game tonight but they're calling for rain. let's figure it out on email...
Youtube channel, 2013 Highlights vid. Ebike Nerdcast.
Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

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