Masini Extremo build scooter with >30kw

[dominik h]

Today I reassembled my scooter.
The controller has a 18W Fan with a seperate temperature switch underneath the grey venting cover , to cool it on hot days.
The QS10 charge plug has now got an extra 150A fuse, because I do not want to have unfused wires running through my scooter.

I had to add a 3.3K resistor to the motor temperature wires because my controller has only KTY81-130 listed and my motor has kty83-122 installed. Now the values at 140C are identical and thermal protection does not cut power to early.



The controller has another problem since I solved the mess in the ratios of speed. The regen does cut the throttle until the wheel stops completly. At my first testrides it worked perfect and the regen power was controlled with the throttle.
Now I have to turn off regen.

I need a new firmware.

 

[dominik h]

First charging test with >1C 8.5-9.5kw
Battery stays cool.
I can raise up to 160A but my power cable to the garage is 40years old an can not handle more. You still see my not perfect connection to cell 11 and 21 with 55mV cell difference. Without charging current it was 6mV.

 

[j bjork]

The problem with the regen not letting go until the bike stoppes happened to me when it was setup wrong. There are 2 values to setup, one has to be bigger than the other. If that is wrong, this is what happens.

 

[dominik h]

Thanks for the Info.
The lower is shown as 40A and the higher 60A.
Problem is the software does not let me change these values at the moment, so I can't try other values.

 

[dominik h]

I sorted a few things. The App has let me change some values.
Brake and sidestand do now cut the motor.
Regen works now with the brakes.
Problem was the max Value had to be raised and the ratios had to be lowered.
The variable regen with the throttle does still not work. But i think the closed throttle has a wrong voltage value. I did tests on the main stand and with very less throttle the motor starts to spin and does not stop when the throttle is realesed, but the app does not let me change the value.

Some new measurements
0-100kp/h 1400pA 400bA
I let the controller reduce current above 95kp/h as I have fear killing my BMS uphill.



400bA are reached in less than 1.5 seconds.

 

[dominik h]

I sorted a few things. The App has let me change some values.
Brake and sidestand do now cut the motor.
Regen works now with the brakes.
Problem was the max Value had to be raised and the ratios had to be lowered

Today it cut power two times with activated regen. Shown Error was "undervoltage" and the controller changed from "MTPA" to "weak" at around 350rpm after 2 seconds regen. Battery SOC was at 70% , so no reason for an undervoltage or overvoltage alarm.
I tried to raise stop back and max back values for 40/80A to 60/120A and during saving the controller changed the values to 4/6A and now the new App does not let me change the values.
I had to take my old phone with the 1.5.5 and change the values back , but I had to change to the new phone with the 2.4.9 to save the values.
That is still a big Ssoftware mess.
Next week I will try the Ios App.

 

[dominik h]

One Issue could be found with cutting out regen. It is definitly not a controller problem.
My JK-BMS is cutting the regen current, when the battery is colder than set in the temperature setting, and then the controller gets in trouble when regen is activated. If it was a Sabvoton it would already be dead. But the Fradriver mangages and survives even this situation.

I set the undervoltage temperature in the BMS to 14C and the release to 14.1C, Problem is that it does not allow charging current under 14.1C but heating ist turned on at 14.0C. That is not how I wanted it to be. Before I had a seperate heating controller set to 14C and the BMS did cut charging at 0C. Probably I have lost my possibility to preheat my battery to a desired value for better performance.

I also have found a Firmware for the ND721800 in the internet.
Problem ist that I do not know if it fits my controller.
Firmware is ND721800_63_ARA24
Controller is ND721800_63_ARG15

 

[dominik h]

New small charging setup
2x Flatpack S 1800W in series.
73x83x260mm or 41.5x146x260mm . 2kg max 37,5A
The Flatpacks are smaller, lighter and more quiet than my previous Vertiv R48-2000E3 setup. The Vertiv turn up their fans to nearly full speed under 48V even without load.
I still have to test what this Duo will do at 70V and I have to get a new plastic Cover, the one on the picture is from a previous Eltek Flatpack 2 HE Setup.

 

[dominik h]

I'm still working on the can code for the delta 48V 3000W rectifier (the one on the left) which is only a little longer as the Vertiv R48-2000e3.
The Delta is 1.3kg at 3050W. The Vertiv .is 1.13kg and the Eltek on the right is 0.85kg. Two Delta in series with a 30V 3.2kw supply will make a 5kg three phase 9kw charger.

 

[erthservnt13]

Impressive machining to make the battery fit and widen the swingarm. impressive all around. I must say that I really like the colors as all of my builds are green, black, & white or silver. Thank you again for documenting & sharing the details. Upon successful reconfiguration with a far driver controller, larger battery and new front suspension, I will do the same. Peace & Blessing,
Erthsrvntxx

 

[dominik h]

New 0-100kph measurement. Battery fully charged and @30°C
With 400Adc

And 450A dc

 

[dominik h]

The Eltek Flatpack S Duo does not charge my battery when it is discharged to 70V. After a minute they turn off.
I have to find a Flatpack S 24V to bring this small charging Setup to work.

Meanwhile I also bought a few used Vertiv R48-1000E3.

I had bought two new ones over two years ago, but did not want to solder on them, so I never tested them under load. Now I also found a compatiple plug for them.
With only 0,6kg and 41x52x152mm they are small and lightweight, the downside is, the do not accept permanent voltage settings under 48V.

 

[dominik h]

Bought an Eltek Flatpack S Rack with 24V 1000W rectifiers and a smartpack Controller.


I changed my Flatpack S charger to one 48V 1800W and a 24V 1000W connected in series. This makes nearly 2,7kw charging power from empty to full. All the voltage drop while charging my empty battery is done by the 48V Flatpack. Th2 24V only reduces its output voltage by 0,2V.