DD 9C 2810 - Cntrl Lyen 18Fet 4115 - Battery 38120HP & CADP

DD Hub Motor 9C 2810 in 26" wheel $150.00 USD methtek.com
Controller C7225 (72v 25A shunt to 40A) $125.00 USD methtek.com
Cycle Analyst CADP $120.00 USD methtek.com
Battery Headway 38120HP 8AH 28S1P DIY designed 0.25" thick T6 6061 nickle plated Aluminum busbars, no BMS, HX-JST's $700.00 USD

I sent Methods an email with items for purchase. Methods sent me a price breakdown and paypal email. Shipped to Up State NY in 5 days
Methods is amazing at answering questions. Communication is topnotch!
Hub motor in 26" wheel was in Double Cardboard. Extra items inside were bubble wrapped and taped securely.

This is build #4. I like to build, fix, design things. First electric propulsion project was made from off the shelf products
not designed for ebike propulsion. lol see: Electric pusher trailer in signature block. I was Comms/Electronics in Military for 22 years.
VE7TAC Amateur Radio Op. I can wire a house from Meter base/panel/outlets complete.

I been using this new build for 2 weeks. Although the FS Mountain bike was my son's 10 birthday present 9 years ago, he didn't use is much and it is in mint condition. (I've been eyeing it up for a while now.....lol)

I didn't weigh the 9C2810. First voltage was 12s1p 38.4v nominal Pack (41v off charger) and 24kph (had to start somewhere).
Second voltage was 24s1p 76.8v nominal (82v off charger) and 45kph. (now we are getting somewhere)
Third voltage was 28s1p 89.6v nominal (95v off charger) and 55kph (hold on... nice torque)


What's nice about high voltage is that my speed increased, but my Watt Hours per Kilometer remained very close. (same course/near same conditions)
38.4v 19wh/km @ WOT 24kph 600-1000 watts (battery pack 10lbs)
76.8v 24wh/km @ WOT 45kph 1000-1500 watts (battery pack 20lbs)
89.6v 24wh/km @ WOT 55kph 1000-1600 watts (battery pack 23lbs)
190lbs rider
Rear tire is Bell Beach at 60psi
Front tire is stock mountain knob at 60psi
3.6ah used over 13km
0.5kw/h to recharge entire pack [Pack split into 3 (2x 12s1p on 2 x 37v/2a chargers) and (1x 4s1p on 12v/2a Venom charger)]
@ 80% DOD to expect 23km distance at WOT with moderate pedaling.



CA-DP IMHO is a must! I have it set to 28amps max. So @ 28amps and 95v 2660 watts with peaks around 3000 watts
The Cycle Analyst keep track of wh/km or wh/miles, amp hours used, distance traveled etc... It's your FUEL GAUGE! ... never run on empty!



The 38120HP 8ah Headway do not drop below 3.1v with a 2C load (1500 watts) In my case... 17amps at 87volts.
And.... 3.07v 4.375C (3,000 watts) 35amps at 86 volts. I'm liking high voltage set ups



ELEVATION MAP:
http://flic.kr/p/bF1qxs

Cool, and good info. Any pics?

Anyway, with my Clyte HT3525 (also from Methods), Lyen 124115 controller and 30S (126V) 2P (9Ah) Lipo, I get similar watt consumption. If I take it easy, I am down to 22 Wh/km. In my normal commutes it is more like 30 Wh/km due to fast acceleration, high topspeed, etc. I max out at 82 km/h on the CA, which is around 76-77 km/h on my GPS. At 9Ah (around 1'1kWh) and 30 Wh/km, I usually get a range of 25-30 km before I really need to recharge.

hjns said:

Cool, and good info. Any pics?

Anyway, with my Clyte HT3525 (also from Methods), Lyen 124115 controller and 30S (126V) 2P (9Ah) Lipo, I get similar watt consumption. If I take it easy, I am down to 22 Wh/km. In my normal commutes it is more like 30 Wh/km due to fast acceleration, high topspeed, etc. I max out at 82 km/h on the CA, which is around 76-77 km/h on my GPS. At 9Ah (around 1'1kWh) and 30 Wh/km, I usually get a range of 25-30 km before I really need to recharge.

Click to expand...

WOW! I really appreciate the return info! I would like to do another build..... I'm Hooked! I wasn't sure if it was going to be HT or the HS.
I've ordered the LYEN 184115 86-132v. I'm very excited to up the voltage some more. Nice to see your figures. I'm shooting for 70-80km next build.
Also, you could change your Wheel Circumference on the CA to slight larger number to match your GPS if you'd like :wink:

Tommy L sends... Pics coming soon!

HT or HS, depends on what you need. If it is just speed on the flat, go for the HS, and it will seriously scream at 28S (>80km/h). If you have serious hills, the HS will get too hot too fast, so get the HT. Alternatively, get the Cromotor, should handle everything you throw at it.

I know, I know I should calibrate the speedo. Too many things to do....

Note that if you go for power, the 100V 100A controller (Methods) or the Lyen 184110 version is probably the way to go, due to the lower resistance (and therefore less vulnerability for heat) of the IRFB4110 MOSFETs as compared to the IRFB4115 FETs. The maximum peak current I got from the 124115 controller was 80A at 126V (10kW), and I have been told that that is already over the edge, so I backed off in order to prevent smoke. With the 18 FET version, obviously the power is divided over more FETs, so you should be fine.

Anyway, neither 9C nor HT/HS is capable of doing 10kW sustained without rigorous cooling. So watch the temperatures in both motor and controller when going above 5kW.

Here with the Pictures!

I must thank my son as I hijacked his FS Hooligan bike for this build!










Tommy L sends....

Should be able to read this one now.




Tommy L sends....

red headways... nice.. the round cells take up a whole lot of space but they make repairs a walk in the park compared to all other types of cells.. ( repairs on lipo are no fun !! )

time for vids ! 8)

Ypedal said:

red headways... nice.. the round cells take up a whole lot of space but they make repairs a walk in the park compared to all other types of cells.. ( repairs on lipo are no fun !! )

time for vids ! 8)

Click to expand...

The "RED" Headway are holding voltage above 3v per cell at 4.5c You are absolutely correct on the repair portion, although I haven't had to, it will
make it easy Some people might not like the High Voltage. I can add one more cell to 29S1P without going over 100v, but I'm not going to push it.
I've already ordered the 4115 18fet 86-132v from Lyen! lol

Yes yes yes.... vids to follow. I purchased a GOPRO Hero2 and it's awesome. I shot vid on the first ride. I haven't edit the vid yet.
I shall do it! And I'll get out at 96v and shoot more video!

This FS Hoolagan feels stable at 55kph

Tommy L sends....

editing and uploading to youtube are a royal timesuck... i hope you got a good upload speed connection on your hands..

Ypedal said:

editing and uploading to youtube are a royal timesuck... i hope you got a good upload speed connection on your hands..

Click to expand...

Yes... Time sucker! and NO we are in country 4g wireless snail band lol. Lap top is still trying to allow Ace Mega Pack codecs to operate.
I don't usually make movies from the laptop, but the main computer was being used. Working on it! and now it is late. Isn't that always
the way? Don't make me go ORANGE...... no no no lmao!

I really did try to get some video up here tonight!

Tommy L sends....

Here with the vid!

[youtube]G297JB_gWOM[/youtube]


This video was shot prior to the beginning of this build thread. Although I came back from the ride knowing that the CA reports non accurate numbers, I have already solved the problem. I've never used a CA before and I had thought that the CA-DP "direct plug in" would automatically figure things out from whatever controller was plugged into it. .........lol Wishful Thinking! lol Shunt value on back of controllers must be entered into the "ADVANCED" programming of the Cycle Analyst

Tommy L sends.... \\m//

Nice vid Tommy. Double check your CADP's calibration to your controller. It's likely that the calibration is off ... hence the generous (but erroneous) values of Ah, watts, etc. reported by your CA. Get the RShunt value of your controller and make sure it is enterred properly in the Advanced Setting's Menu of your CA.

yeah.. it's not horribly off but you are showing more power than you are actually using imo....

what do you have " Rshunt " set to at the moment ?

and when you say " sunted to 40 amps " exactly how did this get done ?

Sacman said:

Nice vid Tommy. Double check your CADP's calibration to your controller. It's likely that the calibration is off ... hence the generous (but erroneous) values of Ah, watts, etc. reported by your CA. Get the RShunt value of your controller and make sure it is enterred properly in the Advanced Setting's Menu of your CA.

Click to expand...

I was so excited to just get the vid up I had for got that we worked that out. I've never set up a CA before. I didn't enter the SHUNT value, because I didn't know

With the Shut value input correctly into the CA.... 24wh/km and 3.3ah used over 13km

\\m//

Ypedal said:

yeah.. it's not horribly off but you are showing more power than you are actually using imo....

what do you have " Rshunt " set to at the moment ?

and when you say " sunted to 40 amps " exactly how did this get done ?

Click to expand...

My bad.... Although I didn't put the info under the video in this thread, I did put it in the YouTube description, explaining that I entered correct Shunt Value into the CA

Methods did the mod on the C7225 controller. He put the value on the back of the controller. I had no idea that I had to enter shunt values into the CA.
My thinking was..... It's a CA-DP direct plug in..... it should deal with everything automatically! lol

It was my first video prior to this Build Thread. Beginning of thread is accurate figures.

I will shoot video with the 95.5v The 9C 2810 at 76v 32amp was nice, but at 89v and 28amps and although both add up to 2400 watts the higher voltage
is awesome! I'm going to continue to maintain watts of 2500 to 3000 while climbing voltage \\m//

Tommy L sends.... \\m//

[youtube]wm1lgjJiQ0o[/youtube]

Pre 95.4v ride video


Tommy L sends.... \\m//

[youtube]gVI28ai0U24[/youtube]

95.4v ride.....

Tommy L sends..... \\m//

Dig the videos thanks for sharing. My 2810 should be here early next week. Plan on pumping 2kw+ for 15-20 minutes through it climbing 1,600ft to work at 72v30A. Will at least air cool drill if not oil bath. Can't wait to abuse this little motor. 8)

pwbset said:

Dig the videos thanks for sharing. My 2810 should be here early next week. Plan on pumping 2kw+ for 15-20 minutes through it climbing 1,600ft to work at 72v30A. Will at least air cool drill if not oil bath. Can't wait to abuse this little motor. 8)

Click to expand...

Curious if you picked the 2810 based on my vids. It's nice to have input to decide what motor/volts/amps required to do certain jobs.

If you do a build thread, please PM me. I very interested in your two choices of cooling and your results

Thank you for checking out my build...


Tommy L sends..... \\m//

Nice thread and nice vids, Tommy.

I like my 2810 very much. Used it for 2WD at 20S. Now adding a temp sens and replacing the wires to allow for 30S (126V HOC) with a Lyen MK2 12 FET 150V controller. See if it eats 10kW...

Tommy L said:

Curious if you picked the 2810 based on my vids.

Click to expand...

I've been building ebikes for about 5 years now. I chose the 2810 for this summer's commuting season strictly based on price... cheap! I was also tired of having a heavy Clyte 504 build that weighed like 90lbs. Trying to go light(er) this time around.

hjns said:

Nice thread and nice vids, Tommy.

I like my 2810 very much. Used it for 2WD at 20S. Now adding a temp sens and replacing the wires to allow for 30S (126V HOC) with a Lyen MK2 12 FET 150V controller. See if it eats 10kW...

Click to expand...

Thank you!

This is exciting! You must PM me with the results!

Your 2wd setup is..... 1 or 2 controllers? not sure if 1 controller is possible?
I'm interested in hearing more. Was it more efficient running two 2810's over one 2810? I believe it would be, if your journey
has many starts and stops.

Tommy L sends...

pwbset said:

Tommy L said:

Curious if you picked the 2810 based on my vids.

Click to expand...

I've been building ebikes for about 5 years now. I chose the 2810 for this summer's commuting season strictly based on price... cheap! I was also tired of having a heavy Clyte 504 build that weighed like 90lbs. Trying to go light(er) this time around.

Click to expand...

So sorry! After I asked..... I saw that you are 1MW

You have much experience and I appreciate your knowledge.

I did go with the 2810 for price/weight/other reviews and more learning for myself.

It's great to see people COOLING them with oil or air holes. I'm only running 2.5kw max on burst and at 55km 1 to 1.5kw. On 70F or 20C days the motor
is warm to the touch. I hate to see what the inside heat is like. I guess it's time to learn about cooling and temp sensors! lol

Tommy L sends.... \\m//

Just got back from another ride/workout. I like to pedal

23C or 73F Yes... when the air is warmer it is less dense! Hit 64kph/40mph ohhhhh yawwwwwhhhh!

Wind was 15kph/10mph (on my course
22wh/km
Top speed 64kph/40mph
Avg speed 48kph/30mph
Distance 13km/10miles
Pack start voltage 96v
Pack under 2500watt load 86v (3.072v per cell)
pack under 1000watt load 89v (3.179v per cell)

What also helped was I topped up the batteries. My 37v charger puts out 41.3 and my 36v nom split LiFePO4 should get 43.4v.
So I used my Venom hobby charger and topped up all the cells and got a whole 1-2v more! lol

I charge two 36v and one 12v and put them all in series for 96v

Tommy L sends... \\m//

Tommy L said:

Just got back from another ride/workout. I like to pedal
23C or 73F Yes... when the air is warmer it is less dense! Hit 64kph/40mph ohhhhh yawwwwwhhhh!

Wind was 15kph/10mph (on my course
22wh/km
Top speed 64kph/40mph
Avg speed 48kph/30mph
Distance 13km/10miles
Pack start voltage 96v
Pack under 2500watt load 86v (3.072v per cell)
pack under 1000watt load 89v (3.179v per cell)

...

Tommy L sends... \\m//

Click to expand...

Tommy - both I and Kinni420 have the 2810 in 26" wheels, getting pretty similar numbers to what you are reporting. The 2810 is nice at over 70v and awesome at over 90v. We're running 18S LiPo, I've experimented with 24S (100V HOC) and it's been fantastic, 40mph possible to maintain at WOT. I love how the motor can handle peaks over 2Kw and not get hot to the touch.