1st e-bike build, 22S A123 AMP20

[ninja007]

I've been lurking on this forum for years, learning lots and hoping to start my e-bike project. Well the time is now here and I'm needing some help finalizing choices. I'm going to mostly use the bike for recreational mountain biking, but possibly a periodic 10 mile each way commute to work as well. Help me spend my $1500 budget! (not including batteries and frame that I already have).

Frame: my trusty Jamis hardtail I've ridden for the last 10 years.
Motor: I'm into big power, but I want to keep my mistakes inexpensive as I learn, so i'm leaning towards starting with a geared hub motor, most likely the MAC from Em3ev.
Controller: Really like Lyen's controllers, but will probably go with whatever comes with the motor, 40 amp
Battery: 22S A123 AMP20. I picked these up from OSNPower, they are cut tab cells, but at $18 ea. the price was right. I've done a lot of thinking about that packaging and design of the pack and i'm excited to share that as I go through my build.
Charger: I blew up my Hyperion 1420i, want something I can effectively do battery testing / logs charge statistics etc
BMS: Really need some help here, I dont want something that's going to castrate these cells potential at dumping 400 amps into a cromotor someday, but still want adequate LVC protection. What are some good options out there?
Extras: CA V3

Remind me if I left anything out. First thing up, just got some materials in today for the battery case build!

 

[Drivesolo]

I've been lurking here fore a while now too. I saw your announcement of this project on FB and I'm interested in following your build. Best of luck to you on it! Looking forward to reading all about it.

 

[docnjoj]

Definitely consider Agniusm's kits for those A123 cells. Top of the line design and the price is reasonable.
otherDoc

 

[ninja007]

I've looked at the Agniusm's kit before http://endless-sphere.com/forums/viewtopic.php?f=14&t=38545&hilit=A123
Its a great design, but has a couple problems for my build. First, no 22s, second, I'm not sure if my short tabs would work with his mounting setup and third, this is one area of the build I want to have some fun DIY style.

I found Bestech referenced on a different thread for BMS, anyone have experience with these, or know where to actually buy one?
http://endless-sphere.com/forums/viewtopic.php?f=14&t=50207&start=50
http://www.bestechpower.com/pcmbmspcbforlifepo4batterypacks/

Also in the running for BMS is the FoundingPower, it looks like pretty amazing, it has android app and bluetooth connection so you can monitor your pack with your phone, and it has unlimited current, but it looks like if you want all the features and support you have to pay twice as much to the sole source european dealer. Or order it cheap from the manufacturer on alibaba but not have features/support.
http://endless-sphere.com/forums/viewtopic.php?f=14&t=40774&start=100
http://www.foundingpower.com/en/Products/Smart_BMS/2012081492.html

 

[ninja007]

I decided that my first step is going to be testing the batteries before I build them into a pack, which means I need to get my charger working again. It's a Hyperion 1420i I used when I was making motorcycle and car batteries out of A123 26650 cells. That experiment didn't turn out so great, i've managed to kill all of the packs I built mostly due to neglect, letting them over-discharge in the car/motorcycle. Then when I attempted to revive one of the packs, I somehow managed to smoke my charger. I posted up in the Hyperion thread to see if I can get some help:
http://endless-sphere.com/forums/viewtopic.php?f=14&t=23362&p=910257#p910257

Here is basic information from the manufacturer about the handling of these batteries:
https://www.endless-sphere.com/forums/viewtopic.php?f=14&t=51435&start=0

Here is some abusive testing of the batteries:
http://endless-sphere.com/forums/viewtopic.php?f=14&t=15093&hilit=Testing+the+big+15+20Ah+LiFePO4+cells+is+tough!+*Pics*

I remember reading a NASA article on these batteries a while back that is important to test these batteries for soft short defects, which cause a slow drain and can end up ruining a pack by draining it if it sits for long periods. So my plan is to cycle the batteries once, then discharge to 2.0V using some DIY resistive load tester then let the cells sit for two weeks, periodically checking voltage to see if it plateaus like it should or of it starts dropping.
here it is:
http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20120000040.pdf