Budget Electric Bike Project

[averhamdave]

Hi all. I'm going to run this thread whilst I build up my project bike in the next few days. I hope to post some pics as I go.

Whilst not a contender for e-bike of the year I hope it will function OK and that the thread will be of interest to some.
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The Specification:

Its built around an old 21.5" Giant Boulder 21 speed mountain bike that has no suspension.

The whole bike has been with me for the last couple of years and comprises entirely of parts I have sourced FOC from the scrapman and assembled into a decent bike! The FOC bit is, course about to cease!

I have a Powabyke front hub which I will use eventually - subject to the rest of the thing functioning OK. I say hub because it came to me as a 24" wheel which I have stripped in readiness for building into a 26" rim.

For now though I will be "borrowing" the front wheel from my regularly used Powabyke Euro - (26 inch, 36v, brushed, geared).

I have the 36v 15ah "cheap lipo from China", a nice "topbox" to carry it and a controller just arrived from E-Crazyman (thats a 36v, brushed, 500w unit - low voltage cut out 31.5v, max current 30a). I already have a spare throttle and don't intend running any pedelec. These Powabyke motors have a good freewheel system and can be pedalled very easily without power.

As a special treat for the old Giant, I have also just bought a pair of Scwalbe Marathons and new Scwalbe tubes!

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Will it work? Does anyone foresee problems? I have a question on the next post for NRG or anyone else who can help.

Dave

 

[averhamdave]

My question relates to the controller wiring. This arrived this morning from e-crazyman and as like the last one I bought for the torq, comes without instructions.

Can someone help with the wiring please, where I have indicated I am unsure):-
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Heavy Gauge red and black to one plug - POWER IN (yes?)

Heavy Gauge yellow and blue to one plug - To MOTOR (yes?)

Light gauge black and yellow to one small plug (and marked "brake") - BRAKE CUT OFF (yes?)

Light gauge red and blue to one small plug (and marked "power locks") - I DON'T KNOW - is this to ON/OFF switch???? I'm going to be using an keyed ignition barrel.

Light gauge red and black to small plug (and marked "indicator") - IS THIS A "POWER ON" indicator that would be wired to an indicator lamp?

Light gauge red, black and blue to a plug (and marked "to put") - I'm assuming this is to throttle?

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Thanks, I'll take a picture later - when the camera hs charged up!

Dave

 

[mechaniker]

My question relates to the controller wiring. This arrived this morning from e-crazyman and as like the last one I bought for the torq, comes without instructions.

Hi dave,
you can connect the way you have written, this is all correct.

BTW, to connect the motor, blue and yellow, be carefull when use the throttle, maybe it turns backward. If it turns backward you must change the blue and yellow to the motor.

the small red and blue for ingition, when it is closed, the controller work and when the cable is open the controller is switch off.

The battery-status is not necassary to connect.

If you drive by throttle, also the brake is not necassary to connect because i dont belief that you want use throttle and brake at same time

regards
frank

 

[averhamdave]

Thanks for the input Frank.

How does the small red & black "battery status" work? Does it just indicate "on" or "off" or can I attach a voltmeter and take an actual condition reading?

 

[mechaniker]

Thanks for the input Frank.

How does the small red & black "battery status" work? Does it just indicate "on" or "off" or can I attach a voltmeter and take an actual condition reading?

On this cable is the normal battery output so you can attach a voltmeter that shows you the actualy volt, but i dont like this kind of batterystatus because it is not relly exactly, it´s more a view into a crystal-ball ;-)

A good batterystatus is the cycle-analyst or wattsup or maybe a new series from a china cockpit look´s also good for that, in 2weeks i know more because i have ordered some sample. With this you have the same function as with the CA but a bit cheaper and better designed

regards
frank

 

[averhamdave]

A good batterystatus is the cycle-analyst or wattsup or maybe a new series from a china cockpit look´s also good for that, in 2weeks i know more because i have ordered some sample. With this you have the same function as with the CA but a bit cheaper and better designed

Look forward to hearing your feedback on that Frank. Until then I'll leave the bike without any sort of meter.Was this the sort of thing you are looking at?

3½ DC 200v Blue LCD Digital Volt Panel Meter Voltmeter on eBay (end time 12-Jan-11 20:01:01 GMT)

Thanks, dave

 

[jbond]

The cheap lipo is LiFePo, yes? In which case you might want to adjust the controller's LVC. Or you can rely on the battery's BMS LVC.

The Powabyke hub is a re-badged Bafang? And it's sensorless?

 

[averhamdave]

Thanks for the input "jbond". I've tried to answer your questions below. You raise some interesting points for me!

The cheap lipo is LiFePo, yes?
Yes the one discussed in an earlier thread

In which case you might want to adjust the controller's LVC.
I wouldn't know how to do this - actually doubt its possible on this relatively cheap controller

Or you can rely on the battery's BMS LVC.
That's what I was going to do!

The Powabyke hub is a re-badged Bafang?
Is it? I didn't know that. Certainly of a very different configuration to the one on my Ezee Torq, different gearbox, good freewheel mechanism

And it's sensorless?
Yes, its brushless, sensorless - just two wires from the controller!

Dave

 

[flecc]

I think the new Powabyke motor is differently sourced and probably specially designed. They spent quite a while searching for a suitable replacement for their old but powerful motor, the SB options wouldn't have taken any time at all to find.
.

 

[NRG]

If it got two wires from the controller to the motor then it's a brushed motor.....

 

[averhamdave]

If it got two wires from the controller to the motor then it's a brushed motor.....

Yes, typo on my part, it's a 2 wire brushed motor. Pretty old one at that!