Yet another BBS02 build, BeOne Nirvana 2.0

[Overclocker]

So I snagged a NOS new old-stock BeOne Nirvana f/s frame in the correct size (for me, 19"), and has ample triangle space, so I figured why not turn it into another ebike

BBS02 2016 production w/ upgraded FETs:

BBS02 custom settings. 22A limit to avoid heat issues. PAS0 and PAS1 set to the same 1-1. The reason for this is that since PAS1 is the bootup default I want my BBS02 to startup w/ PAS disabled i.e. to avoid accidentally throwing me off a cliff

Battery is Sanyo NCR18650GA 3500mah. 13s4p. No BMS, will simply have external balance port for occasional balancing. BBS02 set to 38V LVC which is just about right for 13s when using these NCA cells w/ 2.5V end voltage. To be charged using a DC-DC boost module:

Details of boost module charger here: https://endless-sphere.com/forums/viewtopic.php?f=14&t=82731


Build in progress...

 

[Overclocker]

slow progress...

kapton tape between cells. bonded w/ neutral-cure black silicone. donut insulators on positive end

7mm x 0.15mm pure nickel welded w/ JP Welder

will do parallel connections next...

 

[Overclocker]

instead of doing multi-layer nickel at the pack + & - i prefer doing this. 12ga stranded copper for good current distribution, w/ pre-attached nickel tabs, then finally welded onto the cells

 

[Overclocker]

the C695 display doesn't show voltage, it only has a bar which doesn't calibrate with the LVC values that you've actually programmed into the controller

so a voltage display is needed. i selected this one:

https://www.aliexpress.com/item/A96-Free-Shipping-Battery-12V-24V-36V-48V-Capacity-Tester-Indicator-For-Lead-acid-Lithium-LiPo/32440878092.html

see youtube link for PDF documentation:

[youtube]py_LKc1Zt7w[/youtube]

6.94mA draw w/ backlight:

0.13mA draw, backlight off, LCD active:

 

[Overclocker]

 

[Overclocker]

ran it down to LVC, which happened 100m from my house. i actually wouldn't mind pedalling this because it's so lightweight

 

[Overclocker]

took me up this mountain no problem 8)

 

[Overclocker]

just did a full discharge test of this 13s4p Sanyo GA pack using this nichrome wire contraption. 615Wh. shall test again a year from now to see capacity loss

 

[Overclocker]

finally finished the battery box. the cells are bonded to the aluminum shell w/ thermally-conductive silicone

 

[tln]

Awesome build! Is there a story behind the battery box side covers?

Looks lightweight, whats the final weight (without mud )

 

[Overclocker]

Awesome build! Is there a story behind the battery box side covers?

Looks lightweight, whats the final weight (without mud )

oh the side cover graphic? just my lame attempt at emulating the paint job on the bike frame while hoping that it would make the battery pack look smaller than it really is. TBH i'm not too happy w/ it

final weight? no idea but yes it's pretty light compared to my GNG mid-drive bike

 

[Overclocker]

it's been a flawless 3000 kms for the bbs02

i also added a handlebar-mounted voltmeter

 

[Overclocker]

same 6.8ohm load

i'm still getting 95% of original capacity after 14 months and over 4000km

new X-fusion rear shock, and testing a different fork:

 

[Lyo]

Looks really neat - how far can you go on a full charge?

So is that right the BBS02 would be the best option for a full suspension; lightweight e-bike, floating typ of e-bike
in comparison to all the hub-drive bikes out there?

I really want to get an e-bike or build one myself; I am living in Germany therefore many bikes and parts I don't want to order from the US too much of a hassle

Thanks for sharing bro!

 

[Overclocker]

Looks really neat - how far can you go on a full charge?

So is that right the BBS02 would be the best option for a full suspension; lightweight e-bike, floating typ of e-bike
in comparison to all the hub-drive bikes out there?

I really want to get an e-bike or build one myself; I am living in Germany therefore many bikes and parts I don't want to order from the US too much of a hassle

Thanks for sharing bro!

hi. i have a post about range (w/ pedalling) earlier on this thread

yeah the BBS02 is a great choice for MTB use, but it can be difficult finding a compatible frame. you need something w/ a straight downtube, and you don't want suspension parts near the BB area. on top of that you want a large space in the triangle for the battery pack

 

[Lyo]

60KMs wow rock solid
thanks for your advice!

that would be my kinda e-bike

then I firstly need to find a good price/quality BBS02 Kit, and a battery pack - would be good to get it from Germany;
inexpensive shipping and no import taxes

I actually just recently started working in a Bicycle Work-Shop here in the Allgäu, repairing bikes and e-bikes.
Unfortunately they are just selling the 'legal' kinda e-bikes there which are pretty poor at 25Kmh max speed here in Germany

 

[Overclocker]

here's something for you Sanyo GA haters :lol:

i tested the capacity of this pack when b-new, then 2 more times in 14 month intervals

no capacity loss between april 2018 and june 2019 8)