72V ebike - falcon v2 (bomber?) 7kW (12kW)

szczur333

1 mW
Joined
Jun 15, 2020
Messages
19
Location
Poland
Hey, there is my ebike
Story starts in 2016 but with lack of knowledge and later on, lack of freetime, my first build got constantly delayed, so I choose to pay someone to funish it for me. I finally hit streets in September 2019.


PARTS:
- frame: falcon v2 (made in my country, I believe this is some sort of bomber copy)
- battery : 20s14p sony vtc5 (35Ah)
- controller: sabvoton 72150
- motor: QS205 5T
- BMS: 20s generic (100/10)
- charge port XLR with 5A charger

During this 5 years I personally modified my ebike.
Most of modifications was done around charging capabilites. Replacing generic bms by ANT 150/50 bms. Also I tested about 10-12 different chargers and (I ended with 2400W moded rectifier for trips bcoz of size and light weight) I had also r4850g but it was very loud and hot even at low power
Story of charge ports:
- XLR (5A at first, later 10-12A - at 10A it was very very warm)
- XT60 (25-30A)
- DUAL XT60 (25-30A + 26A) my record of charging speed - total was about 55-56A - 20-90% under 20minutes with total of 4 chargers connected in parallel
- silver high amp (30A) socket (didnt remember name exactly)

and FINAL and IMO best charging port:
- anderson 50A, i know its BIG but this is advantage - its easy to plug in comparasion to xt60
I also modified my rectifier for better look (I broke my leg in summer so I HAD TO do something)

Next mods in 2025 - new wiring insdie and outside for better look.
 

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and FINAL and IMO best charging port:
- anderson 50A, i know its BIG but this is advantage - its easy to plug in comparasion to xt60
Genuine andersons do a great job for stuff you don't mind being big; they stay connected when they should, and have the sacrificial tips so sparks don't damage the conducting surfaces. :) You can also get housings that are pre-keyed in various ways so that if you have multiple things with them on there, you can't accidentally plug the wrong ones together. ;)

Is this
3D printed? If so, would you be willing to post the file for it? There's probably a number of people that use the SB series andersons for charging that would appreciate being able to have a "handle" housing for it. (my charger is built into the SB Cruiser trike so I don't need a handle like that, but there are others that could use it).
 
Nice and clean. But the crankset looks kinda out of place, like it's there just so the thing can pass as a bicycle. Foot pegs would match it better.
 
handle I downloaded some time ago:

inlet for anderson is custom (I try to upload file later)

its not fit perfectly - bcoz I didnt know how to draw this* in 3d, so I printed smooth version of it and connect by 4 self tapping screws - its rock solid

EDIT//
inlet with 5mm to edge is added - before it was 7,85mm but it was too long, maybe 6mm will be enough but dont check it yet
 

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Nice and clean. But the crankset looks kinda out of place, like it's there just so the thing can pass as a bicycle. Foot pegs would match it better.
I WAS analog biker before, I am pedalling a lot at lower speeds - sometimes its helps to make better range on longer trips, also I like to trigger car/trucks drivers while I am doing full speed (80-85kmh) by pedalling "in air" :ROFLMAO::devilish:
 
what is the 2.4kw rectifier
server/telecom power supply - can be moded as adjustable volt/amp battery charger + cc/cv module is added - rectifiers has high power density, mine is 230x104x85mm which is about 2L and about 2kg only.
I can get about 29A real amps - in comparasion gtk charger 30A (24 A real) was 4kg and twice this size

Higher density rectifires exist of course but for me noise factor was importnantas well, mine is little bigger and has 80mm fan, even at 1000W is silent

sticker of my exact model, now its gone due charger chassis is grinded and polished ;)
 

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charger final look (I think)
 

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anyone with sabvoton 71250 ?

I move halls to another socket (gx12-6pin) so 3 pin are off
so I missing USB pins
 

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