Motorino XPn Chinese ebike (scooter)

Was able to fully figure out the issue with my buddies bike, the screw holding the switches were loose and when I checked my bike and compared it to his I saw that was the issue, and repositioned the switch and tightened the mount screw and no more problem
Jim
 
Hey there's been cold nights lately so I've been using the battery warming system I made. It works totally awesome. The warming mat is wrapped around the battery. The thermostat is set to 24 degrees Celsius. The outside row of cells in contact with the mat never go over 27 degrees. The heat from the outside cells radiates to the center of the battery in a matter of a few minutes, keeping the whole thing at a constant temperature.

EDIT: My scooter sat in the parking lot at work all day in the rain today and I rode home in the rain. I had no issues with the kill switches with the covering I put on them.
 
How'd you make your battery heater? We haven't had any really cold nights yet, but knowing Calgary weather, it could be -30 and a half meter of snow any day now.

Do you leave it heating all the time, or do you just warm it up when you're riding or charging it? I understand these batteries should be fine to store at temperatures down to -40, but charging or discharging at that temp is bad for them.

How much draw on the battery does it have? I imagine it takes at least a dozen or so watts, do you know how long the heater would take to completely discharge your battery?
 
It's an 80 watt battery warmer from Canadian Tire. This warmer wired to a 110V digital LCD thermostat I found on ebay is plugged into a wall outlet. It's not getting it's power from the battery. I plug it in and leave it plugged in all the time while the scooter is in the garage so that the battery stays at a constant 24 degrees Celsius. The battery box is lined with rigid insulation to keep the heat as constant as possible.

http://endless-sphere.com/forums/viewtopic.php?f=10&t=30112&start=300#p917942

On a different note, I got an email that I should receive my two winter tires next week. I bought two Heidenau Snowtex M+S 120/70-10. This should help a lot riding this winter.
 
Winter has arrived with a bang in my town. So I got to trying out the new mud and snow tires I installed on my scooter. They do give me way much more traction than the regular scooter tires I had before. I also enlarged the wind screen with a piece of acrylic I found in the shed to cut the amount of cold air getting under the helmet on my chin and neck. I also made a little extension to my helmet's visor for even more protection from the bitter cold. Everything works as it should and I'm very pleased with the results. I still feel the cold of course but the windscreen and visor really take the "sting" out of it. The battery warmer is doing its job of keeping the battery warm in the garage, but sadly, after more than three and a half years of riding this to work, I still can't plug in at work because of a stubborn manager. A few pics.

On the left is an original Kenda 3.50X10 tire that came with the scooter when new. In the middle is a Michelin S1 110/80-10 I replaced the Kendas with. And on the right is one of the Heidenau Snowtex M+S 120/70-10 all weather tire I am using for this winter.

tires_zps4c991259.jpg


The large piece of Acrylic I put over the small windscreen I had. The top is at level with the tip of my nose. It gives very good protection against the wind. The whole screen is high lighted.

large_wind_screen1_zps731e9a78.jpg
 
Where were you able to get the tires and how much were they
 
Hey Mistercrash, which controller was it that you were using before? Lyen? And did it give you a noticeable improvement in performance over the stock controller?

I just ended up smoking mine. Not sure what happened, I think some water got into it when the temperature warmed up and the snow and ice started melting. Looks like there was some fire. Large sections of pcb have vaporized.

So, I'm not sure what to get as a replacement. Do you know how much motorino charges for a controller? How much did you pay for the lyen?

Thanks!

PS: Did you end up getting regen working? I really doubt this had anything to do with my 48v mod, but I wonder.
 
The Lyen controller I had was the 18fet one. Not much more performance than a modified stock controller but the ability to program it was a good option. It was still a "bicycle" controller and I find it was not suited for heavy scooter use. Motorino charges way too much for their controller, you can get the same thing on ebay for a quarter of what they are asking. Then do the same mods that was done to the stock Motorino controller.
If I get some extra cash one day, I'll be going for a Sabvoton controller. Now that is more suited for small motorcycles that ride in the rain and snow. That coupled with a cheap 4kw 10" hub motor would give a lot more torque and speed than what we have right now.

With the split shifts I'm doing lately, I haven't found the time to do any work on the scooter. I have a 48V relay with connector to install to eliminate the big spark that occurs in the ignition switch when turned on, I have the 12V relay to install to get the regen back. But that regen mod makes me nervous now that I read what happened to your controller.

EDIT: I just thought of someone in Oakville that installed a small Kelly controller in their XPn. This would be another good option and less expensive than a Sabvoton me thinks. With no options, it looks to be about the same price as a Motorino controller.
http://endless-sphere.com/forums/viewtopic.php?f=2&t=62617

This is a second thread they started after the installation.
http://endless-sphere.com/forums/viewtopic.php?f=10&t=62666
 
Hmm... That kelly controller looks like it could be a really good option.

Yeah I'm not really sure what happened. I sorta doubt it was caused by the regen mod though. I'm not sure how it could cause that. This seems more like a short or something. :(

PS: Here's where I found out about that mod: https://www.endless-sphere.com/forums/viewtopic.php?f=7&t=6132
 
10300km on the counter and I blew the stock controller I was running for a while now. I don't think I can do much to fix it and I am not wanting to fix it as I am looking to replace with a much better one. Just don't know which one yet.

EDIT: After some emailing and phone calls with two companies, I'm leaning towards buying a Kelly. The KLS7250D. It seems to be programmable enough to limit the amps and motor speed so I can use the small motor and battery I have now and reprogram for real power and speed once I upgrade.
 
Bought the Kelly KLS7250D controller, a 12V 400amp contactor, the cable and tablet for programming the controller. Now shopping for wires, connectors, a sealed push button switch etc. here is the schematics I came up with looking around at what others have done to their motorcycles at ElMoto forums.

XPn%20wiring%20diagram_with_kelly_ca1_zpsc25qvreu.jpg
 
Finishing up on the mechanical overhaul while waiting for parts to come in for the Kelly install. Took the whole scooter apart and checked everything and repaired/replaced as needed. Cleaned the whole chassis and re-sprayed. Repaired every crack and hole in the body panels. Still need to re-spray those. It will look like new and should run like new.

chassis2_zpshm35kaqk.jpg~original
 
When you took out the body panels and such how long did it take to take them all off and have a question about the circuit breaker how often has a trip for you mine trips every now and again but i'm not sure if the circuit breaker needs to be replaced or that I am having a load issue
 
It took less than 30 minutes to take all of the body panels off. My breaker never tripped but when I took it off, I knew I would not re-use it so I opened it and the contacts are very small, they were also black and some of it was eaten away by sparks because of the times I used the breaker to shut off the system. That breaker is 40 amp I think, you could get a proper ANN fuse with fuse holder to replace that breaker, something like a 60 amp or 100 amp fuse maybe.
 
So at the moment you have a 2kwh battery pack, a 500w 10" hub motor and you are waiting for your ~10kw capable controller.

How many amps / volts were you pushing with the lyen 18 fet? I assume it uses 4110 fet.

What was wrong with the 18 fet controller?

My current scooter has a 1500w motor and puts less than 2500w to the road. Load is over 200kg. Controller is a 18 fet (stp75nf75) as well but I blew it (and repaired it) already.

I have already ordered an 18 fet from em3ev and I hope for it to handle over 3500w ~50v ~75 amps. Battery is a 1.8kwh pack for now.
 
Yes I was waiting for a 10kw capable controller with my little 2kw/h battery and 500w motor. I received the controller and I am waiting for more supplies to come in to finish the job... For now. The plan for the near future is to pair this controller with a 6kw hub motor and a 74V 72ah battery made of Tesla cells. But for now, the controller is adjustable enough to use the small battery and motor.

My Lyen stopped working a long while ago, it looked like water got in it judging by the corrosion I found inside. I put back the stock controller and ran with that until it blew a few weeks ago. That is when I decided to stop messing around with bicycle stuff on what is basically a small motorcycle. So I am installing small motorcycle stuff, hoping to create a very dependable little commuter capable of a top speed of 75 km/h and sustain that speed until the LVC kicks in without burning up the motor, which will run without tranny fluid in it or whatever or without a bunch of holes drilled in it to try to cool it. But the goal is not to go at top speed all the time, the goal is to use the thing like a sleeper, puttering around town at no more than 50 km/h. No stress on the system and hopefully no cops bothering me.

A nice little commuter that will run dependably for 4 to 6 years without major repairs is what I'm looking for. Not something I have to work on for hours every weekend.
 
Just had a little test drive on my lead sled. I don't have measuring equipment but I can give rough numbers.

-60A rated 18 FET controller
-4 x 12V 40Ah SLA batteries
-250 kg total system weight inc 100 kg rider
-60 kmph top speed ("gearing" / voltage limited)

Assume 2500 W from battery.

I would say the performance is similar to a elite road cyclist sprinting all the time everywhere. Not as fast as a velodrome sprinter though.

I am in no hurry, and can keep up in city traffic just fine. Although some insist on overtaking, I just meetup at the next light.

Extended climbs are worrisome as controller and motor cooling are not sufficient for under 20 kph climbs.
 
I was able to do a little work on the scooter today. I installed the fuse holder on a piece of sheet metal I put to stop any splashing water from getting to the battery. You can see that the controller sits on the back of the chassis, over the rear wheel, bolted to a solid sheet of metal. The contactor is bolted to the side above the controller. It's tight but it'll work.

fuse_holder1_zpsuipiscrx.jpg


On one side I installed the small DC/DC I've been using for 4 years and the two relays I will use to turn everything on. Missed a bit of rust in that pipe. I'll have to take care of that.

dc_dc_relays1_zpsephbdmry.jpg
 
The wiring is almost done. I have to put the battery in. I have to connect the phase wires to the motor and insulate them. I have to find something to cover that main fuse. I want to make a check list to go over everything to make sure I got it right. Then I can connect the battery and turn on the system and see what needs debugging in the controller. And I also have to finish repainting all the body panels. Yeah! I guess I'm not almost done.

kelly_chassis_wiring1_zpsvhyrks80.jpg


kelly_chassis_wiring2_zpspfvom62m.jpg


kelly_chassis_wiring3_zpsxpbiyglr.jpg
 
diff_lock said:
how did you crimp those huge wires? or are they just soldered?
Click to expand...

They are soldered. I talked with a fleet mechanic, an industrial electrician and they both agreed that if you don't have a good crimper than soldering is perfectly acceptable if I followed a simple technique they showed me.
 
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