jkbrigman
10 kW
Alan B said:
Alan - have your BMSBattery chargers worked OK for you? I always wondered if maybe a different charger from BMSBattery would have lasted longer.
CroBorg Super Commuter
- Thread starter Alan B
- Start date
Alan - have your BMSBattery chargers worked OK for you? I always wondered if maybe a different charger from BMSBattery would have lasted longer.
Alan B
100 GW
I have two of the BMSBattery Alloy chargers, small ones, probably 200 and 400 watt models. I had them set conservatively, so 2 amps at 75V or 150W for the 200W model, and 4 amps at 75V or 300W for the 400W model, and they have been completely trouble free with these larger than usual safety margins. Their ratings are probably optimistic so they hold up better with reduced loading.
This minor instance was my fault, I connected the 200W model wrong, and as far as I can tell the only problem is the output fuse popped. I replaced the fuse and measured the output voltage, it was about nominal, but I haven't tried using it to charge the ebike yet. I switched to the 4 amp model and that is a bit nicer since it completes sooner. I'll have to try the 2 amp unit again but measure and monitor it more carefully than usual.
The Borg did its usual yesterday and this morning, chewing up those commute miles quietly. This morning I must have passed slow/stopped traffic for three miles or so, and the weather was perfect for a morning commute.
The challenge is going to be staying cool enough this afternoon, yesterday it was rather warm on the way home wearing the tourmaster gear, and today is even warmer. I'm going to try taking the liners out and opening the vents. I really like the feeling of some "armor" on the skin and bones. My foot still hurts a bit from last year's fall. But it is hard to stay cool with that gear on.
This minor instance was my fault, I connected the 200W model wrong, and as far as I can tell the only problem is the output fuse popped. I replaced the fuse and measured the output voltage, it was about nominal, but I haven't tried using it to charge the ebike yet. I switched to the 4 amp model and that is a bit nicer since it completes sooner. I'll have to try the 2 amp unit again but measure and monitor it more carefully than usual.
The Borg did its usual yesterday and this morning, chewing up those commute miles quietly. This morning I must have passed slow/stopped traffic for three miles or so, and the weather was perfect for a morning commute.
The challenge is going to be staying cool enough this afternoon, yesterday it was rather warm on the way home wearing the tourmaster gear, and today is even warmer. I'm going to try taking the liners out and opening the vents. I really like the feeling of some "armor" on the skin and bones. My foot still hurts a bit from last year's fall. But it is hard to stay cool with that gear on.
Alan B
100 GW
Freewheel Failure
This morning I was enjoying the beautiful ebiking weather on the way to work. About a mile from my destination I noticed a gritty feeling in the pedal drivetrain. It appears the Dicta freewheel has failed. It is still allowing freewheeling at high speed, at low speed it tugs mildly at the pedals.
I have a brand new White Brothers freewheel that I was planning to use initally, but it won't fit in the narrow space available.
This morning I was enjoying the beautiful ebiking weather on the way to work. About a mile from my destination I noticed a gritty feeling in the pedal drivetrain. It appears the Dicta freewheel has failed. It is still allowing freewheeling at high speed, at low speed it tugs mildly at the pedals.
I have a brand new White Brothers freewheel that I was planning to use initally, but it won't fit in the narrow space available.
Alan B
100 GW
Riding ChainLess
Removed the chain for safety while the new freewheel parts are on order. Very strange feeling, not being able to add thrust by pedaling.
But the ebike grin was good this morning sliding past several miles of cars stacked up waiting for the one lane road to get through a few lights. I turn off before town and wind through the park, so I don't get stuck in the stoplights.
The next challenge will be getting the old freewheel off. I'm not certain the tool (on order) will fit over the massive bolt in the CroMotor Hub.
Removed the chain for safety while the new freewheel parts are on order. Very strange feeling, not being able to add thrust by pedaling.
But the ebike grin was good this morning sliding past several miles of cars stacked up waiting for the one lane road to get through a few lights. I turn off before town and wind through the park, so I don't get stuck in the stoplights.
The next challenge will be getting the old freewheel off. I'm not certain the tool (on order) will fit over the massive bolt in the CroMotor Hub.
jkbrigman
10 kW
Alan B said:The Borg did its usual yesterday and this morning, chewing up those commute miles quietly. This morning I must have passed slow/stopped traffic for three miles or so, and the weather was perfect for a morning commute.
This week, I sat in traffic (going home) for an amount of time equivalent to the total time it would have taken me to do the commute on my ebike. I was stunned.
In both cases, the traffic was triggered by accidents or rubbernecking cops stopping other motorists. Traffic here has gotten insane. So much so that today it's nearly 8pm and I'm only just now leaving work, to completely avoid the horrible traffic here. (we had storms today so I could not easily have ridden anyway...I am almost positive there was horrific traffic out there today. Any time we have storms, people drive too fast, hydroplane and spin into the median barrier. It happens so often, it's almost a certainty.)
So I got chastised, severely, by the bad traffic for not riding the e-bike this week. All I could think about was how I could have ridden around it all in the ebike. Instead, I sat in an idling Ford F-150 the whole way, seeing the $$ tick off in my head.....
Alan, keep enjoying your (currently chainless) 'Borg. I'll try to join you next week with the Phat Bike....
Alan B
100 GW
How Frustrating! Traffic and bad weather doubles the pain!
It is almost too hot in the afternoon to ride with my safety gear on. The last two days I waited till 7PM to come home due to heat and extra work was another factor.
Good luck.
I'm waiting for tools and parts to tackle the freewheel repair.
It is almost too hot in the afternoon to ride with my safety gear on. The last two days I waited till 7PM to come home due to heat and extra work was another factor.
Good luck.
I'm waiting for tools and parts to tackle the freewheel repair.
jkbrigman
10 kW
Alan B said:
YES! It was frustrating and a very serious lesson to me. I'm in a phase right now where I'm trying to cut expenses and accelerate saving for retirement. I wish I hadn't burned that 1/4 tank of gas and instead used the ebike. We have perfect weather forecast here for Monday and it is my concerted intention to be on that damned ebike come Monday!!!
The whole way home, I thought of your website where you show how an ebike can "improve the mpg of large vehicles". Thanks for that, BTW. I think it's very important to point out that ebikes can displace gas used by inefficient vehicles to much higher $$ gain.
EXCELLENT on waiting for it to cool down but keeping the safety gear on. I don't have enough safety gear, working on that now.
Alan B
100 GW
Safety Gear
After my fall late last year I went looking for better safety gear. Ended up with Tourmaster jacket and pants, and Bilt boots. The Tourmaster jacket has lots of yellow-green reflective material for visibility. Both the jacket and pants have zip-out liners that allow for some adjustment of insulation. They are both supposedly waterproof, and they appear to be, but I'm not planning on testing that. They have armor in the important spots. I can pedal in them just fine, as long as it is not too warm. In the morning it is fine, in the afternoon I take off my shirt and just wear a tshirt under the jacket, and with a double zipper I can unzip both top and bottom somewhat. With very lite pedaling I'm pretty warm by the time I get home, mostly on the lower half.
Of course I use gloves and helmet as well.
It appears as though my repair parts won't arrive today so I'll not be able to fix the ebike this weekend. I can still ride it with the chain off, but Monday I need to take the truck. Hopefully I can leave early enough to avoid the worst of the traffic.
After my fall late last year I went looking for better safety gear. Ended up with Tourmaster jacket and pants, and Bilt boots. The Tourmaster jacket has lots of yellow-green reflective material for visibility. Both the jacket and pants have zip-out liners that allow for some adjustment of insulation. They are both supposedly waterproof, and they appear to be, but I'm not planning on testing that. They have armor in the important spots. I can pedal in them just fine, as long as it is not too warm. In the morning it is fine, in the afternoon I take off my shirt and just wear a tshirt under the jacket, and with a double zipper I can unzip both top and bottom somewhat. With very lite pedaling I'm pretty warm by the time I get home, mostly on the lower half.
Of course I use gloves and helmet as well.
It appears as though my repair parts won't arrive today so I'll not be able to fix the ebike this weekend. I can still ride it with the chain off, but Monday I need to take the truck. Hopefully I can leave early enough to avoid the worst of the traffic.
Alan B
100 GW
Freewheel Tool for Cromotor
Excellent News!!
The new Freewheel and Park FR-6 tool DID ARRIVE today, and I immediately set to work. Do you want the good news first? OK, the Park FR-6 FITS OVER THE CROMOTOR AXLE! I was concerned about all the freewheel tools that had to be drilled or ground out to fit over the axle, and the Cromotor's axle is thicker than most. One challenge down.
Now for the not-so-good news. It doesn't fit over the threaded tube the freewheel screws onto, and on my motor that sticks out as far as the freewheel. The tool's teeth have an inside diameter that is too small.
More good news, though. I chucked the Park FR-6 into the lathe and touched it with a file, and it didn't glance off. So I mounted a carbide cutter and turned out the teeth until they cleared the motor's freewheel mount. Sharp eyed viewers can see the cuts on the inside of the tool above. Easy on a lathe.
The rest is just labor, take a big wrench, remove the freewheel, grease the threads, put the new freewheel on, remount the wheel (no easy task on my Borg), redo the tiewraps, reinstall the chain, reinstall the tensioner. Whew. Remember to retighten the wheel nuts daily for the next few rides.
I wonder if, from now on, I should change the freewheel when I change the tire (3,000 miles or so). This Dicta freewheel lasted a bit over 4,000 miles. Or would oiling the freewheel really help? What to the bicycle experts say? Is there a better freewheel that will fit in this tight space?
Excellent News!!
The new Freewheel and Park FR-6 tool DID ARRIVE today, and I immediately set to work. Do you want the good news first? OK, the Park FR-6 FITS OVER THE CROMOTOR AXLE! I was concerned about all the freewheel tools that had to be drilled or ground out to fit over the axle, and the Cromotor's axle is thicker than most. One challenge down.
Now for the not-so-good news. It doesn't fit over the threaded tube the freewheel screws onto, and on my motor that sticks out as far as the freewheel. The tool's teeth have an inside diameter that is too small.
More good news, though. I chucked the Park FR-6 into the lathe and touched it with a file, and it didn't glance off. So I mounted a carbide cutter and turned out the teeth until they cleared the motor's freewheel mount. Sharp eyed viewers can see the cuts on the inside of the tool above. Easy on a lathe.
The rest is just labor, take a big wrench, remove the freewheel, grease the threads, put the new freewheel on, remount the wheel (no easy task on my Borg), redo the tiewraps, reinstall the chain, reinstall the tensioner. Whew. Remember to retighten the wheel nuts daily for the next few rides.
I wonder if, from now on, I should change the freewheel when I change the tire (3,000 miles or so). This Dicta freewheel lasted a bit over 4,000 miles. Or would oiling the freewheel really help? What to the bicycle experts say? Is there a better freewheel that will fit in this tight space?
Alan B
100 GW
FAILURE
Cruising up the hill from work, the controller apparently failed.
Cruising up the hill from work, the controller apparently failed.
cwah
100 MW
Is it greentime controller? I had the same issue uphill
Alan B
100 GW
No, a 24 FET Lyen. I ride this hill every work commute day, 15% max, 5kw peak, so nothing new there. I usually pedal some, didn't this time. Weather was nice, not really hot or cold. I had a couple of failures early on with this controller, but it has been solid over a year, well over 4k miles. Not sure why it popped today, it is a very demanding hill and I climb it after a couple of smaller climbs, so it may be getting warm inside the FETs. We'll have to see what we find inside the controller, a year of riding on these rough roads may have loosened something up in there. It has been quite reliable for a long time.
I left the bike at work, will take the truck and rack today and bring it home.
I left the bike at work, will take the truck and rack today and bring it home.
cwah
100 MW
Fet popped?
Alan B
100 GW
Likely more than one.
crezzy2k1
1 W
jkbrigman said:Alan B said:The Borg did its usual yesterday and this morning, chewing up those commute miles quietly. This morning I must have passed slow/stopped traffic for three miles or so, and the weather was perfect for a morning commute.
So I got chastised, severely, by the bad traffic for not riding the e-bike this week. All I could think about was how I could have ridden around it all in the ebike. Instead, I sat in an idling Ford F-150 the whole way, seeing the $$ tick off in my head.....
Alan, keep enjoying your (currently chainless) 'Borg. I'll try to join you next week with the Phat Bike....
So ditch the F150, your retirement account will thankyou greatly for it
But i know what you mean, my bike is out of commission due the rear wheel falling apart. Have had to come in the car the last two day, been getting 40MPG but it still annoys me.
Alan B
100 GW
I have a backup controller, 12 FET, and a brand new 18 FET, so I'll get something working this weekend, most likely.
Alan B
100 GW
Rebooted, Backup Controller Online
What a drop in performance! About half power, feels like even less.
But it still rolls along nicely, though the speed is lower on the hills. Stopped and checked the temperature once and it wasn't even warm.
Nice to be back on, always have a spare controller for the win!
The $10 question is, what to do next. Get the 24 FET fixed, move on to the 150V 18 FET that I have sitting in the box, or look into all those new units. There's some good deals on Sevcon's from one place, There's the Adaptto, the Sabvoton, the Kelley, and a few others..??
I would like a nicer throttle response. The present one is fine at full throttle, but a bit uneven at other settings.
I noticed Animalector (?) using ty-wraps to hold the covers on their Borg, that would be easier access, so I tried it. 24" ties just barely make it around, but they do work nicely. They can be slid off and back on if careful, so they don't have to be cut and replaced each time. Re-usable ones might work well also.
What a drop in performance! About half power, feels like even less.
But it still rolls along nicely, though the speed is lower on the hills. Stopped and checked the temperature once and it wasn't even warm.
Nice to be back on, always have a spare controller for the win!
The $10 question is, what to do next. Get the 24 FET fixed, move on to the 150V 18 FET that I have sitting in the box, or look into all those new units. There's some good deals on Sevcon's from one place, There's the Adaptto, the Sabvoton, the Kelley, and a few others..??
I would like a nicer throttle response. The present one is fine at full throttle, but a bit uneven at other settings.
I noticed Animalector (?) using ty-wraps to hold the covers on their Borg, that would be easier access, so I tried it. 24" ties just barely make it around, but they do work nicely. They can be slid off and back on if careful, so they don't have to be cut and replaced each time. Re-usable ones might work well also.
Animalector
10 kW
I went to the local rubber supplier (it's called clarke rubber in Aus) and they sell double sided velcro strap in various widths by the meter ($2 - $5 or so per m), I usually buy like 25mm wide double sided velcro strap and just cut it down the middle if I want a longer slimmer option. likewise for use as re-usable cable ties just cut it thinner and thinner.
Alan B
100 GW
Excellent tip. I have that stuff around here in a couple of widths. It also comes in colors, if I recall correctly.
Do you feel that is a good permanent solution, or merely an excellent short term while in development plan?
Do you feel that is a good permanent solution, or merely an excellent short term while in development plan?
Alan B
100 GW
Windy Day
The wind this afternoon just about stopped my forward progress, and then blow me into the lake. The wife was being blown around so bad in the Prius that she called me and warned me about it. At another point I was going downhill over 30 mph and the wind was moving with me, so no wind noise, force or drag. Very strange. And fun. And tiring.
Thinking about Controllers
And what to do next. Repair the fallen 24 FET? Install the higher voltage 18 FET? Keep on rolling with the modest 12 FET? Get a sinewave controller? I'd like to build my own controller and be able to play with the software, especially throttle and ebraking algorithms. I've been researching design threads here on ES and sketching out schematics. A challenging design and build, as well as a programming effort. Could be very rewarding to use your own code, but also could be very concerning if the code fails to do the right thing with a powerful Cromotor.
Battery Cover Retainers
I'm using three large tiewraps to hold the motor covers on. They are 24" long and just barely long enough, if you are going to do this get the next length up. They work quite well, and can be gently worked off the covers to remove them, and slid back on when done, so they don't need to be replaced. If they were white tiewraps they would mostly blend in, mine are black. I haven't tried the Velcro yet, these are not going to loosen which Velcro sometimes does as it gets re-used.
Gas Tank Refills
Have been riding the ebike so much lately the tank of gas in the 4Runner is lasting, and lasting, and the windshields are getting very dusty. Priceless.
The wind this afternoon just about stopped my forward progress, and then blow me into the lake. The wife was being blown around so bad in the Prius that she called me and warned me about it. At another point I was going downhill over 30 mph and the wind was moving with me, so no wind noise, force or drag. Very strange. And fun. And tiring.
Thinking about Controllers
And what to do next. Repair the fallen 24 FET? Install the higher voltage 18 FET? Keep on rolling with the modest 12 FET? Get a sinewave controller? I'd like to build my own controller and be able to play with the software, especially throttle and ebraking algorithms. I've been researching design threads here on ES and sketching out schematics. A challenging design and build, as well as a programming effort. Could be very rewarding to use your own code, but also could be very concerning if the code fails to do the right thing with a powerful Cromotor.
Battery Cover Retainers
I'm using three large tiewraps to hold the motor covers on. They are 24" long and just barely long enough, if you are going to do this get the next length up. They work quite well, and can be gently worked off the covers to remove them, and slid back on when done, so they don't need to be replaced. If they were white tiewraps they would mostly blend in, mine are black. I haven't tried the Velcro yet, these are not going to loosen which Velcro sometimes does as it gets re-used.
Gas Tank Refills
Have been riding the ebike so much lately the tank of gas in the 4Runner is lasting, and lasting, and the windshields are getting very dusty. Priceless.
Alan B
100 GW
12 FET Toast
A few times I have noticed the 12 FET controller 'cutting out'. It comes right back, so I wondered if there was a poor connection to the throttle or something, but after it happened this morning I pulled over and checked the controller temperature. HOT. It is not getting airflow, inside the Borg panels. I took it easy the rest of the way to work, but it was quite warm, and kicked out one more time before I arrived.
This is one of the newer Infineons, and they have more protection in the software. Perhaps that's why it is lasting on this motor. The motor was warm, the controller was definitely hotter than the motor. Climbing hills warms them up.
So the 12 FET may not be enough for this motor. Mine definitely seems to be marginal, at least with the present setup and cooling.
A few times I have noticed the 12 FET controller 'cutting out'. It comes right back, so I wondered if there was a poor connection to the throttle or something, but after it happened this morning I pulled over and checked the controller temperature. HOT. It is not getting airflow, inside the Borg panels. I took it easy the rest of the way to work, but it was quite warm, and kicked out one more time before I arrived.
This is one of the newer Infineons, and they have more protection in the software. Perhaps that's why it is lasting on this motor. The motor was warm, the controller was definitely hotter than the motor. Climbing hills warms them up.
So the 12 FET may not be enough for this motor. Mine definitely seems to be marginal, at least with the present setup and cooling.
Alan B
100 GW
Repairs
Found a loose wire in the 12 FET controller. This is for the shunt and is causing the wild power readings.
Re-soldered the yellow shunt wire, it appeared to be a cold solder joint failure. This should settle the CA current/power readings down.
On the first day I used this backup controller they appeared to be about double the correct values which is reasonable since I didn't change the shunt value initially. About 3/4 of the way to work the readings soared and became mostly unrelated to the current draw.
I received a new Taylor 9940N temperature probe and readout from Amazon for monitoring the controller.
http://www.amazon.com/gp/product/B001VXZVNG
This unit runs for a long time on a AAA battery and reads up to 150C. Should be adequate for a controller. It has quite a few features for alarms etc that could be implemented, I'm just planning to check it occasionally.
Found a loose wire in the 12 FET controller. This is for the shunt and is causing the wild power readings.
Re-soldered the yellow shunt wire, it appeared to be a cold solder joint failure. This should settle the CA current/power readings down.
On the first day I used this backup controller they appeared to be about double the correct values which is reasonable since I didn't change the shunt value initially. About 3/4 of the way to work the readings soared and became mostly unrelated to the current draw.
I received a new Taylor 9940N temperature probe and readout from Amazon for monitoring the controller.
http://www.amazon.com/gp/product/B001VXZVNG
This unit runs for a long time on a AAA battery and reads up to 150C. Should be adequate for a controller. It has quite a few features for alarms etc that could be implemented, I'm just planning to check it occasionally.
Alan B
100 GW
Fixed the CA Problem
Swapped out the Cycle Analyst with a spare and that fixed the current/power readout. Something in the current sensing has failed on the other unit.
Now this CAv3 has beta21 firmware, so I'll have to dig out the programming gear again. Time to move to the new version...
Worked out a handlebar position for the temperature sensor that fits nicely. Photos later.
The temperature sensor appears to be working, it jumped up a couple of degrees during a quick test run down the street.
Dug out my serial cable and updated to V3 Prelim6. Seems to be working.
Swapped out the Cycle Analyst with a spare and that fixed the current/power readout. Something in the current sensing has failed on the other unit.
Now this CAv3 has beta21 firmware, so I'll have to dig out the programming gear again. Time to move to the new version...
Worked out a handlebar position for the temperature sensor that fits nicely. Photos later.
The temperature sensor appears to be working, it jumped up a couple of degrees during a quick test run down the street.
Dug out my serial cable and updated to V3 Prelim6. Seems to be working.
izeman
1 GW
i had this with my 12fet once as well. the bike suddenly stopped after a long uphll rush at 6kw+ the controller was quite hot, and i guess the wire just fell off due to heat. could this have been an issue with your controller as well?Alan B said:
Alan B
100 GW
The controller was probably quite warm, I didn't know that at the time but have discovered that since, and this was near the hottest point of the ride. The joint was tack-soldered and appeared crystallized and cold. So your hypothesis has some merit, though I don't think it was near solder-melting temperatures. Nothing else was melted that I know of.
I wonder what the safe temperature is for the outside of the controller case? I need to think about that now that I have a temperature sensor there. Today will be the first commute with the new sensor and new CA so I should get some interesting data.
I also checked and the 18 FET controller will just fit in the Borg. It is longer than the 24 FET which fills the space, but the 18 FET can sit a bit higher in the space where more length is available. I'm not sure the 18 FET will run much cooler as the 4115 FETs have higher loss than the 4110's, but I might try it. I will be sending the 24 FET in for repair this week.
I wonder what the safe temperature is for the outside of the controller case? I need to think about that now that I have a temperature sensor there. Today will be the first commute with the new sensor and new CA so I should get some interesting data.
I also checked and the 18 FET controller will just fit in the Borg. It is longer than the 24 FET which fills the space, but the 18 FET can sit a bit higher in the space where more length is available. I'm not sure the 18 FET will run much cooler as the 4115 FETs have higher loss than the 4110's, but I might try it. I will be sending the 24 FET in for repair this week.
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