>>TURBO<< - Simple Multi-Position Switch

[DrkAngel]

Turbo Switch Wiring Diagram
Designed as Turbo function for eZips but easily applicable to any eBike with multi-voltage capable controller.

Simple way to "Legalize" an eBike at ≤20mph 750w ...
Simply flip switch for ≥30mph 1500w motor output (24V >> 48V)... for off road ... ? or "emergency" use only? - :lol:
Or
For more reasonable use:
25.9V LiPo >> 37V LiPo

Center switch position is a disconnect
(Faulty switch could result in short condition! (unlikely but) Do not operate unless both batteries have proper fuse installed!!!)
Simply redirecting 2nd battery (3s 11.1V) neg wire allows a turbo function.

OEM Gearing
Normal - my eZip, 25.9V provides 17mph w/485w motor output.
Turbo - my eZip, 37V provides ~23mph w/695w motor output.

Upgraded to 16T wheel sprocket or 11T motor sprocket
Normal - my eZip, 25.9V provides 20mph w/485w motor output.
Turbo - my eZip, 37V provides ~27mph w/695w motor output.

Any Turbo voltage is possible ... if controller supports normal and Turbo voltages.
eZip MY1018z and XYD-16 motors have survived as high as 48V input if ...
lower Amp controller or stringent throttle restraint at lower speeds.
35A 48V can "burn up" motor and\or shear the sprocket retention key.

I chose 7s (25.9V) plus 3s (11.1V) because I run 25.9V at gearing for legal 20mph.
I have a large quantity of 3s LiPo that can fit nicely in 2nd eZip battery case.
(Can also task 11.1V pack for 12V lighting or inverter use)
Motor has been proven at 25.9V (20,000+ miles on 3 eBikes) and 37V (4000+ miles on 1 eBike)
(27mph, motor only, allows 30mph capability w\heavy pedal assist!) 8)

 

[ferret]

Keep in mind that unless you have a BMS setup to compensate for it, running in "non turbo mode" will cause an unbalance between the cell in the 3S pack and 7S pack, which could cause serious damage.

Another disadvantage is that you are always carrying an extra pack but not necessarily getting any benefit in extra performance or range. If you use a 10S pack and limit the performance to "7S level" in another way (thottle limiting, controller programming, Cycle Analyst, etc.), you will be able to get more range than you would have running a 7S pack (assuming using the same capacity cells of-course). And still have 10S performance potential if you disable the limit.

I would guess that a DC/DC converter/booster would be either too complex, expansive or inefficient, especially at high power levels.

Avner.

 

[DrkAngel]

I promote the "switch" as a Turbo method for several reasons.
KISS© compliant
Cost < $1 each (in lots of 5) 30A capable
3s 50Ah+ compared to 25Ah 7s pack, so my bank level meter monitors 7s base pack with great assurance for plenty of Turbo when needed.
Only carry when wanted-needed.
12V power for lights, horn etc.
AC inverter capable for small tools, radio, laptop etc. etc. etc. ...

For eZips
Switch and controller compatibility (older models) and 2nd battery bay are already present.
Can even hide 3s 5700mAh RC LiPo in rack with controller for Stealth Turbo! (5.7Ah Lipo exceeds OEM 24V 10Ah SLA pack capacity at >1C discharge rate.)

 

[DrkAngel]

12V power for lights, horn etc.
AC inverter capable for small tools, radio, laptop etc. etc. etc. ...

Just remembered ...
3s "12V" add on pack allows use of one important additional function.
inexpensive 12V to 5V usb adapter for charging cell phones, GPS ... much more.