Re: Pchen's Giant DH Team Cromotor-Kelly

[pchen92]

Hi all,


GC advise me to open a thread of my bike,
so I open this thread for my Giant I have just converted to electric.

Motor: HS3540 (going for Cromo soon)
Controller : 12 fets from Lyen (delivers 60A stock)
Battery: either 88,8V 10Ah or 66,6V 15Ah (haven't finished my // harnesses)
Zippy 6S 5Ah ( 6Ah at full discharge )
CA with cut-off @ 84V or 63V

20" rim FTW

I wanted to mount the HS on mid-drive but the chain and derailler problems make me consider 20"rim


How it is now


I put some leds



Video:
[youtube]zN8S_l3w2LQ[/youtube] (the bike hadn't the front 20"rim yet).


Part one [youtube]z8mk7f_5X_o[/youtube]


Part two [youtube]OjH_gJpu-JI[/youtube]


Feel free to ask questions

 

[GCinDC]

nice. subscribed.

Controller : 12 fets from Lyen (delivers 60A stock)

really? i thought stock was more like 30A...

did you lace the rear wheel? might be needing a truing soon.

i was wondering what that wire was... after seeing it in the dark, now i know. :lol:

a lot of wet riding there. be careful if the controller connectors get wet. they'll corrode in a hurry and then weird things will happen...

 

[pchen92]

nice. subscribed.

Controller : 12 fets from Lyen (delivers 60A stock)

really? i thought stock was more like 30A...

did you lace the rear wheel? might be needing a truing soon.

i was wondering what that wire was... after seeing it in the dark, now i know. :lol:

a lot of wet riding there. be careful if the controller connectors get wet. they'll corrode in a hurry and then weird things will happen...

Stock is 45A
I re-lace it in fact. The spokes are now crap. I need to tighten them often :lol:
I bought a big city 20" rim for my Cromo with new spokes :wink:

A few days ago I applied by mistake WOT from a standstill. I wasn't seated and the bike ejected me I teared off the throttle and the motor continued to run :lol:
Now I know I have something really powerfull and touchy between my legs

 

[valsislav]

Loved the videos. 8)
More like, "Welcome to Heaven", judging by your scenery.

 

[electr0n]

Nice setup.

I'm also running an HS3540 at 88.8v and 65 amps but in a 26" wheel. I'm tempted to move it to a 20" wheel for better performance. Are you able to pedal at all? Do you have trouble keeping the front wheel on the ground? Does the motor get hot?

 

[bzhwindtalker]

We should go for a ride one day or another! I need to finish my new bike. The dh looks good with 20's!

Adam

 

[pchen92]

Nice setup.

I'm also running an HS3540 at 88.8v and 65 amps but in a 26" wheel. I'm tempted to move it to a 20" wheel for better performance. Are you able to pedal at all? Do you have trouble keeping the front wheel on the ground? Does the motor get hot?

Sorry for not answering.

Yeah with 20"wheels, the bike has crazy performance. I don't pedal 'cause I don't have a chain
I keep the wheel on the ground because I lean on the front wheel when I accelerate. Otherwise, when you are not prepared to the touchy throttle, you can easily be projected on the ground Like my friends for example :lol:
The motor doesn't get easily hot but I'm lightweight.

I wanted to try the magura throttle so I put off the old throttle. But when I try to accelerate, sometimes it works, sometimes it fails And a few minutes later, nothing worked . The cycle-analyst was still running.
So I opened the controller and I found a loose wire coming from a resistor. Any idea where it should be weld ?

 

[jpgey]

I wanted to try the magura throttle so I put off the old throttle. But when I try to accelerate, sometimes it works, sometimes it fails And a few minutes later, nothing worked . The cycle-analyst was still running.
So I opened the controller and I found a loose wire coming from a resistor. Any idea where it should be weld ?

Hello, both legs from the resistor seems unsoldered. I would try to connect it between Vcc-l and R01b as R01a doesn't exist.

 

[tricky43]

Hi all,

Video:
http://youtu.be/zN8S_l3w2LQ (the bike hadn't the front 20"rim yet).
Part one http://youtu.be/z8mk7f_5X_o
Part two http://youtu.be/OjH_gJpu-JI

Hi Pchen

Great video's, I've subscribed to your youtube channel

I'm building a DH team with 24" wheels

I'd be interested to see a couple of pics of your drivetrain if you don't mind, my bike started as just a frame and I don't have a clue what to put on the front cranks in terms of front chain ring and chain device.

 

[pchen92]

Hi all,

Video:
http://youtu.be/zN8S_l3w2LQ (the bike hadn't the front 20"rim yet).
Part one http://youtu.be/z8mk7f_5X_o
Part two http://youtu.be/OjH_gJpu-JI

Hi Pchen

Great video's, I've subscribed to your youtube channel

I'm building a DH team with 24" wheels

I'd be interested to see a couple of pics of your drivetrain if you don't mind, my bike started as just a frame and I don't have a clue what to put on the front cranks in terms of front chain ring and chain device.

Well in fact I don't have chain and rear freewheel so I can't pedal :lol: You sure want pictures ?

I wanted to try the magura throttle so I put off the old throttle. But when I try to accelerate, sometimes it works, sometimes it fails And a few minutes later, nothing worked . The cycle-analyst was still running.
So I opened the controller and I found a loose wire coming from a resistor. Any idea where it should be weld ?

Hello, both legs from the resistor seems unsoldered. I would try to connect it between Vcc-l and R01b as R01a doesn't exist.

En fait Lyen m'a renvoyé le contrôleur réparé. Je l'ai essayé 10 secondes avant que le moteur ne se coupe à nouveau... J'ai l'affichage au CA mais la partie puissance ne fonctionne plus. La résistance R01B devient brûlante au bout de quelques secondes... Si t'as une idée de ce qui se passe...

In fact Lyen sent me back the controller repaired but when I try it, the motor shut down 10 secondes later... The CA switch on but the motor won't turn (the power part of the controller didn't work). The R01B resistor becomes quickly crazy hot... If someone has an idea of what's going on


Mistake or not, I am about to order a new 24 fets 10kW Lyen controller ! A Cromotor will follow quickly too 8)

 

[pchen92]

Hi,

Great news ! I am about to order 2 Cromotor (one for a friend and one for me).

Do they take 13g spokes ? 'Cause I already have 13g spokes that should work for my 20" rim setup... Or do I need to order 12g spokes and drill my rim ?

I work on my battery setup too. Thinking of going for 23s 15Ah as I have 3 5s 5Ah that I don't use.
I do a little research on the forum and I found out I can't parallel lipo cell with a parallel balance lead for lipo that are already on series.

http://www.endless-sphere.com/w/index.php/Why_You_Can%27t_Connect_Your_Batteries_in_Parallel_and_Series_at_the_Same_Time

So I'm going to make 3 pack of 6s 15Ah and one pack of 5s 15Ah, each pack will have a parallel balance lead for the 3 lipo (so there will be 4 parallel balance lead) and the 4 pack will be connected in series. Looks like a good capacity battery for 35km+ ride at 55km/h

Paul

 

[tricky43]

Will a cromotor fit in the dropouts?

Your DH team is the same as mine a 2003 with 135mm dropouts

I thought you needed 150mm dropouts for this motor http://endless-sphere.com/forums/viewtopic.php?f=31&t=35924

Can you pry the rear triangle apart that far without stressing it so much that it snaps?

The 150mm rear triangle off a 2005 DH comp will bolt straight onto your frame, there's one on UK ebay if you've got a spare £250
http://www.ebay.co.uk/itm/140897421176?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

 

[pchen92]

Yes it will fit because I am going to machine kiwi's adapters a little bit (3mm) and spread the frame 5mm or so. Should be good and reliable I think.

Happy New Year guys Don't drink too much beer

 

[pchen92]

Hi guys,

2 Cromotor are on their way to me
I received the 24 fets monster controller

I work on the battery right now and I have just received my marine kill switch

but I need help because I don't know how to wire it
EDIT: Found (just push the key and turn it)

How can I solder ring plug on my harness to fit on the switch between the 2 nuts ?
Parallel harnesses are almost finished

I'm gonna lace the Cromotor on a 20" BMX rim but at 90V 100A I may not be able to stay on the bike at WOT. If so, I'll go for a 24" rim

 

[dan974]

you need those kind of connector+ shrink tubes Ok, I see yes you just need to push and turn as it is isolated (waterproof) it got a magnet inside
http://www.cloudelectric.com/category-s/12446.htm

and don't forget the precharge resistor 10K if you want to avoid sparks and protect your controller ... next you need to unplugged it, eitherless it will drawn low current from your battery pack when left off...otherless you need a main contactor as me if you don't have a on/off button on your controller...
http://www.cloudelectric.com/category-s/10681.htm

are you sure you'll be able to drawn 100A in that switch ...when I check it the same it was 20 A max I think ...look for a solenoid and this will be used as remote switch...

contactor diagram : https://dl.dropbox.com/u/29701432/ebike/KBL KEB Assembly.pdf - Adobe Reader_2013-01-09_23-42-43.jpg

 

[pchen92]

Thanks for the link

Yeah I am working on a precharge circuit too. I'll set a push-switch (on the handlebar) in this branch to charge the controller when I turn the marine switch on. This way when I turn off my bike (just the marine switch), the battery will be totally disconnected from the controller. Zero current drawn

The marine switch is rated for 100 to 200A continious @12V (depending on the website). No way my bike will do 100A continious. 100A will be for acceleration (6 seconds max). Continious current at top speed will be 35A. I hope this will handle this power.

 

[dan974]

I think you can put more continous ...with big phase wire and regarding your controller capacity and battery C rate too =)...cromotor can handle lots of Amps I think as heavier as HS5400 cause of more bigger hubs...but don't froget to put fuse and a shunt if you don't got it, did you take Cell man controller ?
next time I'll maybe try those ones...http://www.aliexpress.com/store/group/Electric-Vehicle-Controller/313864_211689768.html
few guys use them on the forum...greetime controllers...
bon courage =)

 

[pchen92]

I think you can put more continous ...with big phase wire and regarding your controller capacity and battery C rate too =)...cromotor can handle lots of Amps I think as heavier as HS5400 cause of more bigger hubs...but don't froget to put fuse and a shunt if you don't got it, did you take Cell man controller ?

I take a Lyen controller

Received my Cromo



Right one has an external wire. EDIT: second hall set 8)

It's a pita to lace it on a 20" rim one cross so I'll go for 24" rim

 

[pchen92]

I do the "power-throttle" mod.

I solder two wires on the CA (Vi and G) but I don't know to which throttle wire Vi and G correspond. Magura throttle has a brown wire (wiper), blue (+5V I think) and black.
So blue should go to controller directly, brown to ground and black to Vi ? Or am I mistaken ?

 

[dan974]

Magura throttle has a brown wire (wiper), blue (+5V I think) and black.
So blue should go to controller directly, brown to ground and black to Vi ? Or am I mistaken ?

I think you got it here :http://www.ebikessf.com/node/110

Magura throttle pinout

black = ground
brown = out
blue = +5v

what is the benefit of the magura throttle ? 45$... ?

 

[pchen92]

Thanks !
Reliability, no dead spot (linear), high quality built, ...
It's the common throttle for electric motorcycles

 

[dan974]

=) I just readed once that if you run a full throttle (not thumbs or 0.5 twist) it by law not a bicylce any more ...anyway you're using a Cromotor...which a scooter hub motor :lol: :lol: :lol:
I beguin to think that I'll next put all the balance plugs in a big jack to a have a rapid check as hyena, GinDCD...

 

[pchen92]

I haven't look at their setup for balance wires. Do you have a link ?

 

[dan974]

I think they use the parallel port to wire every balance wire and then make an harness to balance check the cells by pack...no need to open the hard case...
I need to investigate ...next step...the bike isn't even running now ...will 3D print dropouts tomorrow...

http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=14842&start=2925

http://www.winfordeng.com/products/brksd25.php

http://endless-sphere.com/forums/viewtopic.php?f=31&t=41107&start=15

http://dx.com/p/bc168-1-6s-8000ma-200w-high-precision-lcd-intellective-balance-charger-124483

I got the charger and can get 5A @5S with a 250W PC powersupply tweaked...

 

[pchen92]

Hi,

some news, after my problem with the Cro axle, I successfully put the rear disc brake on. Two brakes are a real plus

The throttle is in "speed-mode". But the Magura is very progressiv and not touchy at all Compared to the bike with the hs3540 @5kw, it feels easier and smoother to ride.

I first test the bike on 20" wheels. It was amazing ! I couldn't apply full throttle until 10mph and completely lean on the handlebar It did 20mph+ power wheelies

0 to 30mph in 3sec

But I wanted the bike looks like a bike so I relaced the motor on a 24" wheel. And everything is better, handling, comfort, power consumption, ...

So far I can't fit 12 6s 5Ah in the falcon bag so I ended up buying a im2075 Pelican Case and fork mount, like oatnet did. I am really busy now so I will deal with the Pelican case mod in 2 months.

What's the shunt value of a 24 fets Lyen controller ? I try 0.564 Ohm and it seems quite a good value. 10hp at the wheel 8)

Before:



Smokey burnout



And now:



50 MPH CLUB ROCKKKSS