4 * EnviroSafe parallel load with BXB150-48S05

[Gausi]

Hello
i am Gausi and this is my first entry. Just i bought on Ebay http://cgi.ebay.de/ws/eBayISAPI.dll?ViewItem&rd=1&item=280230789393&ssPageName=STRK:MEWN:IT&ih=018
these cells for an additional Voltage for my 48V scooter. The scooter has 4 times 12V/40AH SLA Batteries original in serial. For a greater range there is an LiFePo4 pack 48V/20AH parallel to the SLA Batts (with shottky diodes). My problem is, that i don´t know who can deliever me 1 time the Artysyn BXB150-48S05? On Ebay there is no offer .... during the charge time i will connect the DC-DC converter to the power supply Eltek SMPS1000Si and to the 1s4p EnviroSafe pack. In Germany scooters with small insurance sign are limited on 45km/h ... directly when i start with my present "battsetup" ( the first 2 minutes )
i measuring 52V by 30A drivecurrent ... and the scooter run 55km/h. With my present "battsetup" i have a range with full power from 85km but only max. speed in average from 45km/h.

Gausi

 

[flip_normal]

Welcome Gausi,

BXB150-48S05 on ebay.com

Are you really getting 85Km range on 48V 40Ah SLA? Got any pics of your scooter, please?

What are you going to do about the low voltage cut-off (LVC) for the LiFePO4 cells? Let them drain completely just once and you could kill them.

 

[fechter]

Sounds like a nice setup. Yes, please post pictures.

Are you using 16 cells in series?

 

[Gausi]

Hi flip_normal

With the original 48V/40AH SLA setup the range by 10C° was 50km .... by 0C° 42km ... the additional LiFePo4 48V/20AH is parallel to the SLA ... yesterday i drove 85km without problems .... the current in normal modus is limited at 32A ...when i climb up small hills or i want faster speedup the controller limit the current to 52A in "power modus".... when i press the power botton the power modus is for 35 sec. after this time the scooter fall back in normal modus. The website from the dealer is:
http://www.solar-mobil-gmbh.de/de/fahrzeuge/solar-scooter.html
my scooter ist the normal SC-25 with SLA setup

The speed is depending at the voltage ... therefore i want place the EnviroSafe in serial to the SLA/LiFoPo4 Batt/Pack
pics from the scooter later ....

Gausi

 

[Gausi]

Hi fechter

all together are b now 64 LiFePo4 cells in 16s4p .... called here "duct-tape"

@ flip_normal

the LiFePo4 pack is a "duct-tape" the LVC i don`t need because the scooter controller stop the current ..... i don`t know by with voltage .... next time i will measure the Voltage ( mayby by 90km )

 

[flip_normal]

The controller will probably have a LVC curcuit in it which cuts the power when the voltage drops below a certain level (~42V?). The problem I see is that the 4p1s EnviroSafe sub-pack, which you're planning to add in series, will have a lower internal resistance than the rest of your pack (being they are higher quality cells) and could dump their charge quicker. Without some form of LVC on this sub-pack you could be risking damage by letting them get over discharged.

Thanks for the clarification on the parallel 48V/20AH LiFePo4 pack BTW, I missed that. That's some useful range you're getting.

 

[Gausi]

Hi flip_normal

You are right .... but this combination 3,3V/40AH to 48V/60AH ( the present SLA/LiFePo4 combination ) i will switch in series when voltage rise down to 48,5 V to hold the speed .... i need the scooter for my daily ride to work ( 53km ) ( i can load there ). After 20km i switch the 3,3V EnviroSafe in series so the hole voltage will rise up ( average drive current ~ 28A ) to 51,8V. Overcharge is not possible ( BXB150-48S05 fixed on 3,65V ) .... overdischarge also not because i need only the 53km . I don`t know how much voltage can have the controller .... but the Elkos inside there have got a max. voltage of 63V ....

Gausi

 

[flip_normal]

Hi Gausi,

Sounds like a good plan.

WOW that's ~500km/week....~25,000km/year. If anyone's going to test the limits of these batteries it looks like you're the one to do it. Keep us posted on how you get on will you? I'm sure there's plenty of people here who will be very interested in your progress. What make of SLA do you have, Greensaver?

If you want to know the capabilities of your controller then if you can take some pictures of the insides and read the part numbers of the mosfets then there are folks here who can help with that and even help to modify it to run at higher voltages. Do you know how the current limit changes? Is it done by the controller or is there a linkage going to the hub motor that mechanically switches coils?

 

[Gausi]

Hi flip_normal

500km in spring,summer and autum is correct, but in winter + during bad weather periods i will use a normal car .... in past was it a very small car ( this picture show it after my accident )

but 12000-15000km i will ride with my SC-25.

The type of SLA i don`t know excactly .... that are PB/SILICON batts ... in normal setup should they have 400 cycles ...the parallel Lifepo4 pack is also important to reduce the peukert effect. Therfore i hope for more cycles.

To the contoller

as you see are the mosfets abraded ... the controller called TSBC-2000
When i push the "power button" the red LED ( you see it on the second picture )lights for 35 sec
The current limit isn`t mechanicall.

Gausi

 

[flip_normal]

Ooch, looks like you got turned into a sandwich! Hope everyone was OK.

The Silicone batts will be Greensavers, they're the only people who make them. There's some useful info about them here, it's a bit of a sales pitch but maybe worth a read.

Your controller is very similar to this one which is good news as we're learning quite a lot about it. Shame they removed the numbers on the fets (I feel for the poor soul who has to do that all day long) but if you wanted to significantly increase the voltage you could replace them with two sets of these IRFB4110s and swap the main capacitors for 100V ones. You'll find lots of info on doing that mod in the E-Bike Technical section.

 

[Gausi]

Hi flip_normal

all was OK ....after that accident i stay only one week at home ....with the silikon batts you are right .... something with green .... was on the label. About the controller i know only that the two blue Elkos ( the lying black 63V type now present ) i changed because the original was "big". When i took the throttle the TBSC-2000 stops the current to the motor. I never heard about a manufakturer SLF

The envirosafe i will get in 10 days by economy air mail from australia ... therefore is enough time to arrange all changes. Till 1100km i drove only with SLA (Silicon) batts ... today i have more than 1800km -> 700km with the Silicon/LiFePo4 combination ...at 1600km i use a "Tempomat" for full speed ...the three wire throttle cable i bridged the green & the red cable with a switch + 1,8 K resistor. For crop up occasion i use the break ...and that will stop the motor because a wire for the break light connect to the controller too. That is easier for my right hand ... one trip is 75min

 

[flip_normal]

The rubbish capacitors in my controller blew the second day I had my moped. They took out some of the fets too, so I replaced them with IRFB4110s and it's been running solidly since. Only 850km on mine but it has been winter (I use it do the shopping) and I need to pedal my bike(s) just to keep fit. You shouldn't need to modify your controller unless you plan on increasing the voltage by more than just a few volts, it should work fine as is with just the extra 3.2V from the series LiFePO4 sub-pack your adding.