Grace One Plus

[Albert_01]

Last year I bought an old Grace One with a dead battery and dead controller.
A Grace dealer said that the price for a new battery and controller is approximitely 1300 euro (!)
For me the reason to modify the Grace One electrical design without modifying the mechanical and esthetical design.

A dead battery (0 volt) and dead controller is very suspicious.
The lack of a BMS in the battery could be the reason for a progressive collapse.
When the controller is leaking current then there is no protection of the battery.
So I think that the controller has destroyed the battery.
Modification: a new battery has a BMS and is located in the old controllerbox.

The original controller has also a switch for the headlights and brakelight.
This part of the controller was brown coloured due to high tempeture.
The controller looks very complicated; it is a combination of functions.
Modification: separation of controller and lightswitches.

The battery has 44 Volt (12s). That is not the standard.
Modification: a new battery gets 48 Volt (13s).

The Grace One has no cruisecontrol en no regen brake.
Modification: add cruisecontrol and regen brake

The Grace One has a dedicated display with RFID key.
The display works tegether with the controller so with a dead controller there is also a useless display.
Modification: standard display, traditional ignition lock and buttons (cruise, speed, light)

The original battery has 4 parts of 44 Volt. The are put together in the controllerbox.


The new battery exists of 4 parts which are connected in serie.
In the upper tube: 8 x 7 = 56 cells
In the seat tube: 6 x 7 = 42 cells
In the old controller tube upper side: 3 x 6 = 18 cells
In the old controller tube dosn side: 2 x 6 + 1 x 2 = 14 cells
Together: 56 + 42 + 18 +14 = 130 cells.
Electrical scheme: 13s 10p
Cell type: Panasonic NCR18650PF (2900mAh)
BMS type: https://nl.aliexpress.com/item/Brand-48v-bms-13S-40A-High-quality-batterie-smart-bms-48v-li-ion-cell-BMS-li/32718848125.html?spm=2114.13010608.0.0.VWZfWZ
The power wires and BMS sensorwires are connected to the BMS in the old controllerbox.
The BMS is fixed vertically on the inside of the cover of the box.

The controllerbox is made of multiplex and fixed on the backseat carrier.
It is made like trapezium.

In the inside of the controllerbox:
- ignition lock (frontside)
- 12 FET IRFB3077 Infineon Controller (EM3ev.com)
- 48 to 12 volt converter (5 amps) for relais and light (H1 halogeen headlight)
- 5 x relais switches: controller, brake, brakelight, light, high/low beam

The Grace One is now a Grace One Plus.
All the mechanical and estetical benifits are present.
A complete new electrical design: more power, flexible, standard and cheaper
Max speed 60 km/hr. Limited to 45 km/hr.
I like it.









View attachment 2

 

[bchaney]

Holy cow, that's a lot of cells. Cool looking bike, looks very heavy-duty.

 

[ninepointeight]

Excellent looking bike, and your addition looks right at home on it. Did those fenders come with the bike? And your switches for the headlights and such- they are inside the box? Seems inconvenient?

 

[ziltoid81]

Great work.

I always wanted to do a similar upgrade to have a bike that i can register (no one will check the bike this detailed to notice the upgrade) but i really dont wanna go 45kmh without suspension.

I would have build a box for the triangle of the frame to fit some good amount of additional cells.

But i dont wanna blame your build in any way, its great, a grace with a real battery and regen brake.
Thats how the bike should be in first place, i never understood why theres no regen.

 

[Albert_01]

Yes, the fenders were there.
The relais are in the new controllerbox. simple to exchange when necessairy.
I didn't put anything but the BMS in the old controllerbox.
The old controllerbox is inconvenient.
So I separated the battery+BMS and the rest of the electronics.
My experience is that the battery is very stable and doesn't need any repair or exchange (for the next 3 years).
The new controllerbox is easy to open.
Disadvantage are the 10 wires at the entrance of the new controllerbox.

The new battery (in the tubes) is 48 Volt (nominal) and 29Ah.

On the controllerbox are 4 boulds to connect a double bag.

 

[Albert_01]

To put 130 cells in the 3 tubes was a hell of a job.
I'll never do it again.
My next ebike will get a triangle battery again.

 

[Albert_01]

View attachment Electrisch schema contact en licht (definitief).pdf

 

[markz]

[strike]Is there a reason for the foam on the bicycle tubes?[/strike] nevermind
Also when you enclose controllers you need to make sure they do not overheat. Airflow over them is good to have.

 

[Albert_01]

Modest airflow through controllerbox. In the bottom front side is a large hole for wires. In de back side there are 2 more holes for airflow.
My experience is that a current of 30 - 40 Amps doesnt need a extra airflow

 

[Frank D. Savian]

Hey Albert.

I also own a Grace One Bike. My charger that came with the bike does not work anymore. Do you know of anyone that has this charger with a Rosenberger Plug that works on the Grace One ?? I've bought other chargers that did not work. Do you know if the charger is a proprietary charger or could I use another brand charger ?? If yes, which one ?? My bike specs are 44.16v and 13 ah.

Thanks Albert in advance for any help you may provide.

Frank.

 

[rdhoore108]

Do you know of anyone that has this charger with a Rosenberger Plug that works on the Grace One ?

Hi Frank, Amazon in Germany are selling it again right now (they didn't have it for quite a while) for €79.99 plus shipping to wherever you live:

https://www.amazon.de/Elektro-Ladeger%C3%A4t-Netzteil-Rosenberg-QQE144-8CH15-L/dp/B079L6YDMN