Put the end of the crimp in the vice heat with torche melt solder in and shove wire into solder. But make sure cold wire doesn't cool the solder to fast as that will cause aa bad joint. Hydraulic crimpers are on eBay for ~$30 and they work great.
Motorino XPn Chinese ebike (scooter)
- Thread starter mistercrash
- Start date
mistercrash
10 kW
Like Arlo said. I smeared the wire with soldering paste first, I melted 60/40 solder in the lug until it was about half full, then I put the wire in the lug leaving the torch on the lug for half a second so the solder does not cool to quickly. Maybe I'll do another one and cut it to see how good the connection is.
mistercrash
10 kW
Here it is, I am satisfied with my connections. Someone owes me a 1 AWG 3/8'' lug.
mistercrash
10 kW
Everything is hooked up and turns on like I planned. Now I'm at the stage where I need to program the controller like I want. But first I am busy repainting all the body panels. I'm going with a different red, the old red was called black cherry, this red is dark cherry metallic. A pic of the front which is freshly painted with the new color and the front fender which has the old color. I'm doing what I can to do the best job possible with spray cans. That front you see had the biggest damage of all the body panels, a big Y shaped crack that started at the top and went down 8 inches.
Customer service at Kelly Controllers is amazing. Fany from Kelly Controllers has been very patient and understanding with me, I feel I have to mention this as he really deserved to be recognized. Thank you Fany.
Customer service at Kelly Controllers is amazing. Fany from Kelly Controllers has been very patient and understanding with me, I feel I have to mention this as he really deserved to be recognized. Thank you Fany.
mistercrash
10 kW
After some confusion about the programming, all my fault, the rebuild of this scooter with Kelly KLS7250D controller is practically done. Just a few odds and ends to deal with. I took it out for a spin and was amazed at the amount of torque this thing has now. It hauls ass! And it does it super quietly, unbelievable how quiet this thing is now. The acceleration is super smooth instead of being jerky like before. And this is with the same little 500W motor I had before with the little 10AWG wires coming out of it and the same little 16S 30Ah battery with the little 8AWG wires which must be creating a huge bottleneck. When I upgrade to a bigger battery with 2/0 AWG wires going to the controller, and a motor with much bigger phase wires, that should give even more torque.
It was a lot of work only because I decided to overhaul the whole scooter instead of just changing the controller. With the help of Fany at Kelly Controllers. the installation of the controller alone was pretty straight forward, I just needed to pay attention to what I was doing
A pic of the scooter all put back together parked in its spot for recharging.
Thanks for watching.
It was a lot of work only because I decided to overhaul the whole scooter instead of just changing the controller. With the help of Fany at Kelly Controllers. the installation of the controller alone was pretty straight forward, I just needed to pay attention to what I was doing
A pic of the scooter all put back together parked in its spot for recharging.Thanks for watching.
mistercrash
10 kW
Here's the set up I am using for the controller right now. It works well, lots of torque and a top speed of 51 km/h confirmed by GPS.
Page 1
Low Volt - 44V
Over Volt - 70V
Current Percent - 100
Battery Limit - 100
Identification Angle - 85
TPS Low - 0
TPS High - 80
TPS Tyep - 1
TPS Dead Low - 25
TPS Dead High - 80
Max Speed - 4000
Max Fwd Speed % - 100
Max Rev Speed % - 100
Start-up H-Pedal - Disabled
Brake H-Pedal - Disabled
NTL H-Pedal - Disabled
Three Gear Switch - Disabled
Boost - Disabled
Foot Switch - Disabled
Change Direction - Yes
Page 2
RLS_TPS Brk % - 10
NTL Brk % - 0
Accel Time - 10
Accel Rls Time - 1
Brake Time - 15
Brake Rls Time - 1
BRK_SW Brk % - 10
Torque Speed KP - 3000
Torque Speed KI - 80
Speed Err Limit - 1000
Page 3
Motor Poles - 46
Speed Sensor Type - 2
Resolver Poles - 2
Motor Temp Sensor - 0
Page 1
Low Volt - 44V
Over Volt - 70V
Current Percent - 100
Battery Limit - 100
Identification Angle - 85
TPS Low - 0
TPS High - 80
TPS Tyep - 1
TPS Dead Low - 25
TPS Dead High - 80
Max Speed - 4000
Max Fwd Speed % - 100
Max Rev Speed % - 100
Start-up H-Pedal - Disabled
Brake H-Pedal - Disabled
NTL H-Pedal - Disabled
Three Gear Switch - Disabled
Boost - Disabled
Foot Switch - Disabled
Change Direction - Yes
Page 2
RLS_TPS Brk % - 10
NTL Brk % - 0
Accel Time - 10
Accel Rls Time - 1
Brake Time - 15
Brake Rls Time - 1
BRK_SW Brk % - 10
Torque Speed KP - 3000
Torque Speed KI - 80
Speed Err Limit - 1000
Page 3
Motor Poles - 46
Speed Sensor Type - 2
Resolver Poles - 2
Motor Temp Sensor - 0
Laserman
100 W
Sweet looks lovely will have to see about getting the controller a buddy of mine has on hold for me and possibly doing the setup with my beast
mistercrash
10 kW
I tried these things I made to protect my knees and thighs from the cold wind. They are awesome, with the big windscreen I made and the four season tires, winter this year is going to be a breeze.
Laserman
100 W
Sweet looking but here in ottawa they use to much fricken salt so my baby is going in for hibernation with some maintence before going to bed, also just saw a bus accident on the news from you neck of the woods hope it wasn't you involved
Jim
Jim
mistercrash
10 kW
Nope, wasn't me. From the start, my plan was to use 18650 cells from a Tesla Model S to build a 74V 72Ah battery for this scooter. After a few weeks of planning, drawing, shopping, calculating, I ended with a total cost that blew my mind. It is a shame because I could have built a 5kw/h+ battery without modifying the space I have in the scooter. So I sent an email to Hybrid Auto Center.com to ask them if they could make an all inclusive battery with 10 Leaf modules of 64Ah much like the large battery they make for the Vectrix scooters. I'm waiting for their answer. I will have to modify the chassis a bit to house those Leaf modules.
granolaboy
100 W
man, you sure have got some mileage out of that motorino 
You got that thing back when I had my gio 500+ POS...
I think you take the award for "most modded motorino" hehe
I'm sure I'd still have my Xph if it didn't get stolen.
Ever think of moving up to something with plates & insurance? You can probably keep up with traffic now.
After losing my Xph, I'm glad I now ride on something with official registration, and $4k theft insurance...
You got that thing back when I had my gio 500+ POS...I think you take the award for "most modded motorino"
heheI'm sure I'd still have my Xph if it didn't get stolen.
Ever think of moving up to something with plates & insurance? You can probably keep up with traffic now.
After losing my Xph, I'm glad I now ride on something with official registration, and $4k theft insurance...
mistercrash
10 kW
granolaboy said:
I would not know what to get for a scooter. EVT is out, Vectrix is out, Xtreme is out, Current Motors make a ''system'' but not just a scooter. V-moto seems out or at least they have no distributor in America. There's only the over priced, under powered Motorino Vespa look alike that I can think of. Plus, after spending almost five years fixing the faults in this little XPn scooter, I'm kind of attached to it. My present top speed is 51 km/h so I can barely keep up with traffic, for a very short while. I still have the 500W motor so I keep the speeds below 40 km/h most of the time.
What are the regulations?
No point in getting a registered vehicle if you can get by with the limitations of an unregistered vehicle.
In EU the regulations suck so most people just drive illegal bikes or pay the cost of operating a road legal bike.
No point in getting a registered vehicle if you can get by with the limitations of an unregistered vehicle.
In EU the regulations suck so most people just drive illegal bikes or pay the cost of operating a road legal bike.
mistercrash
10 kW
diff_lock said:
Right now that is my opinion also, I just want a sleeper that I will putter around town with at the speed I'm suppose to go and sometimes, when there's no cops around, just twist the throttle to top speed and make me smile then ''regen'' back down to legal speed. I got an answer from Hybrid Auto Center and they can send all that is needed to make a clean and professional looking battery with stuff found in the Leaf battery. Bus bars, bolts, threaded rods, compression end plates, plastic covers and channels for the wiring. To save on shipping, I got a US postal address with Kynek. I am also talking with Fany at Kelly controllers about their 6KW hub motor.
mistercrash
10 kW
Ordered ten Nissan Leaf modules with necessary accessories to make a battery. I hope I can make them fit.
mistercrash
10 kW
$1290 USD divided by 4.59kwh would be $281.04 USD per kwh. That would be installed cost as the modules come with the bus bars and bolts to join them together in series, the threaded rods, end plates, nuts and washers to compress them together, and the plastic covers and channels to cover the bus bars and channel wires for a BMS. But you can figure this out for yourself by shopping for what you want at Hybrid Auto Center. Nick was very helpful during the whole process. I am hesitant to spend large sums of money as I don't have much so I always have tons of questions before I buy. I feel I have to mention whenever someone has the patience to put up with me. Nick was awesome.
http://hybridautocenter.com/HAC4/in...ashop&view=category&layout=listing&Itemid=605
I was disappointed that Kelly Controllers don't have the sort of motor I am looking for. Fany was very patient as usual and tried to find something but they just don't have what I want. So I am talking with Vito from QS MOTOR about a 12 inch 5KW V3 motor. QS MOTOR do have a double stator 6KW constant 12KW peak beast in a 10 inch rim but you need two controllers for it. I went to my Motorino dealer to see if the front wheel from an XPd would fit on my XPn and I'm pretty sure I can make it fit so I would be rolling on 12'' wheels with performance tires in the Summer with a 5KW motor and I would go back to 10'' wheels with four season tires in the winter with a 500W motor.
http://qsmotor.en.alibaba.com/produ...60_45H_E_Scooter_Extra_V3_Type_Hub_Motor.html
http://hybridautocenter.com/HAC4/in...ashop&view=category&layout=listing&Itemid=605
I was disappointed that Kelly Controllers don't have the sort of motor I am looking for. Fany was very patient as usual and tried to find something but they just don't have what I want. So I am talking with Vito from QS MOTOR about a 12 inch 5KW V3 motor. QS MOTOR do have a double stator 6KW constant 12KW peak beast in a 10 inch rim but you need two controllers for it. I went to my Motorino dealer to see if the front wheel from an XPd would fit on my XPn and I'm pretty sure I can make it fit so I would be rolling on 12'' wheels with performance tires in the Summer with a 5KW motor and I would go back to 10'' wheels with four season tires in the winter with a 500W motor.
http://qsmotor.en.alibaba.com/produ...60_45H_E_Scooter_Extra_V3_Type_Hub_Motor.html
mistercrash
10 kW
I have been comparing all the different ways to make my own battery, always including all costs related to the build. This ended up being the best bang for the buck. Add to that the ease of assembly, the safe aspect of the product, good customer service. Finally, from the experience of many already who have used battery packs made with the Leaf modules, these cells stay so balanced they are boring.
So I mention I included all costs of building a battery when comparing the different products out there. So I should mention that it cost $192 of shipping, then I will have to pay a fee of $20 to the Kinek address, and finally something like $165 of customs and taxes when I bring them in to Canada. So a total of $1647.00 divided by 4.59kwh equals $358.82 per kwh.
So I mention I included all costs of building a battery when comparing the different products out there. So I should mention that it cost $192 of shipping, then I will have to pay a fee of $20 to the Kinek address, and finally something like $165 of customs and taxes when I bring them in to Canada. So a total of $1647.00 divided by 4.59kwh equals $358.82 per kwh.
mistercrash
10 kW
The leafs are in my possession. 4.5kwh of pure awesomeness. All included with ends brackets, threaded rods with nuts, bolts and screws with bus bars and plastic coverings for the connections. The cells of every modules are at 4.054 to 4.057 V. One of the easiest DIY battery out there. There is still a lot of work for me to do, I am changing my main wires from 1 AWG to 2/0 AWG and I have to make four 5S balance tabs.
This is how I will try to fit them in the scooter, taking all of the room available underneath the seat.
This is how I will try to fit them in the scooter, taking all of the room available underneath the seat.
mistercrash
10 kW
The motor is coming next week apparently, got confirmation from Vito at QS Motors and he was nice enough to take pics and send me a pdf file of the motor's performance.
John in CR
100 TW
Your scoot is going to be in a completely different league than before. Do a good inspection of the strength, especially the swing arm. Wait for the motor to arrive to work on clamping dropouts. Be aware that many scooter hubmotors have the axle flats on different planes, which can become a nightmare if you do perfectly tight fitting dropouts.
mistercrash
10 kW
Thanks John. Part of why I did a complete tear down and overhaul of the scooter prior to these changes was to assure myself that all the parts of the frame, suspension, brakes and everything else was in good condition and up to snuff.
EDIT: Looking at that motor shaft, I might have to have a new custom swing arm made. I'll know for sure when I get the motor.
The Leaf modules are wired with balance tabs and a bulk charging connector.
I plan on bulk charging all week and a balance charge on the weekends to see how well things are going. I also plan on having Cell-Logs connected to the balance tabs, the Cell-Logs should have a much louder alarm that I want to install to warn me if a cell goes too low. I searched for a ''how to'' on how to install a louder alarm on the Cell-Logs. I found an old thread.
https://endless-sphere.com/forums/viewtopic.php?f=14&t=19955
I am going to give it a try. Here's my take on how I want to do it. I am waiting for the parts to come in. On my Cell-Logs the black wire on the alarm output is connected internally to the negative of the battery so I made the change from the drawing in the link.
EDIT: Looking at that motor shaft, I might have to have a new custom swing arm made. I'll know for sure when I get the motor.
The Leaf modules are wired with balance tabs and a bulk charging connector.
I plan on bulk charging all week and a balance charge on the weekends to see how well things are going. I also plan on having Cell-Logs connected to the balance tabs, the Cell-Logs should have a much louder alarm that I want to install to warn me if a cell goes too low. I searched for a ''how to'' on how to install a louder alarm on the Cell-Logs. I found an old thread.
https://endless-sphere.com/forums/viewtopic.php?f=14&t=19955
I am going to give it a try. Here's my take on how I want to do it. I am waiting for the parts to come in. On my Cell-Logs the black wire on the alarm output is connected internally to the negative of the battery so I made the change from the drawing in the link.
mistercrash
10 kW
Got the motor. It looks really nice. QS Motors 12 inch 72V 5kw V3 hub with tubeless rim, 32 poles, curved magnets, 36 teeth. 50X3T of what I measured to be 0.62mm wire. Max phase current of 408A. 1070RPM at 72V that is what... 14.86kv? It has two sets of hall sensors with two connectors. Every screw had blue Locktite on them, the bearing seal had white grease on it where it meets the shaft. The cap was sealed. The bearings are big, 25X52X14 of an unknown brand. The stator center is cast aluminum. The main shaft and nuts are typical Chinese iron. The axle flats are on the same plane. Phases wires are almost four feet of 4 AWG.
My spare 500W scooter hub stator looks puny beside this 5KW stator.
My spare 500W scooter hub stator looks puny beside this 5KW stator.
