Yet another BBS02 build, BeOne Nirvana 2.0

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Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Mon Oct 03, 2016 10:44 am

So I snagged a NOS new old-stock BeOne Nirvana f/s frame in the correct size (for me, 19"), and has ample triangle space, so I figured why not turn it into another ebike :twisted:

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BBS02 2016 production w/ upgraded FETs:

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BBS02 custom settings. 22A limit to avoid heat issues. PAS0 and PAS1 set to the same 1-1. The reason for this is that since PAS1 is the bootup default I want my BBS02 to startup w/ PAS disabled i.e. to avoid accidentally throwing me off a cliff

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Battery is Sanyo NCR18650GA 3500mah. 13s4p. No BMS, will simply have external balance port for occasional balancing. BBS02 set to 38V LVC which is just about right for 13s when using these NCA cells w/ 2.5V end voltage. To be charged using a DC-DC boost module:

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Details of boost module charger here: https://endless-sphere.com/forums/viewt ... 14&t=82731


Build in progress...

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Thu Oct 06, 2016 1:17 am

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slow progress...

kapton tape between cells. bonded w/ neutral-cure black silicone. donut insulators on positive end

7mm x 0.15mm pure nickel welded w/ JP Welder

will do parallel connections next...

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Sat Oct 15, 2016 12:13 pm

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instead of doing multi-layer nickel at the pack + & - i prefer doing this. 12ga stranded copper for good current distribution, w/ pre-attached nickel tabs, then finally welded onto the cells
Last edited by Overclocker on Tue Oct 25, 2016 7:41 am, edited 1 time in total.

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Thu Oct 20, 2016 12:30 pm

the C695 display doesn't show voltage, it only has a bar which doesn't calibrate with the LVC values that you've actually programmed into the controller :roll:

so a voltage display is needed. i selected this one:

https://www.aliexpress.com/item/A96-Fre ... 78092.html

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see youtube link for PDF documentation:



6.94mA draw w/ backlight:

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0.13mA draw, backlight off, LCD active:

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Tue Oct 25, 2016 12:48 pm

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Mon Nov 07, 2016 11:16 am

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ran it down to LVC, which happened 100m from my house. i actually wouldn't mind pedalling this because it's so lightweight

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Sun Feb 12, 2017 10:55 am

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took me up this mountain no problem 8)

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Sun Feb 19, 2017 2:49 am

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just did a full discharge test of this 13s4p Sanyo GA pack using this nichrome wire contraption. 615Wh. shall test again a year from now to see capacity loss

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Sat May 27, 2017 12:11 am

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finally finished the battery box. the cells are bonded to the aluminum shell w/ thermally-conductive silicone

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by tln » Sat May 27, 2017 10:37 am

Awesome build! Is there a story behind the battery box side covers?

Looks lightweight, whats the final weight (without mud :) )

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Sun May 28, 2017 3:11 am

tln wrote:Awesome build! Is there a story behind the battery box side covers?

Looks lightweight, whats the final weight (without mud :) )
oh the side cover graphic? just my lame attempt at emulating the paint job on the bike frame :) while hoping that it would make the battery pack look smaller than it really is. TBH i'm not too happy w/ it :roll:

final weight? no idea but yes it's pretty light compared to my GNG mid-drive bike

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Sun Jun 18, 2017 10:27 am

IMG_20170618_181249 (Medium).jpg
3k km
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it's been a flawless 3000 kms for the bbs02

i also added a handlebar-mounted voltmeter

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