GT i-drive 2.0 Build

[GCinDC]

Correction: Hitting brake doesn't power off CA, it merely removes characters so CA appears only backlit...

Also: After 15-30 seconds of turning my on switch, voltage goes from 81.7 up to 92.3V and hovers there...

So something is funky w/ CA. I've got both my new 116 and old 846 open side-by-side and am comparing connections. Not a lot similar!

It's gonna take some concentration and patience to note the locations of each 'pin'.

[nicobie]

Correction: Hitting brake doesn't power off CA, it merely removes characters so CA appears only backlit...

Also: After 15-30 seconds of turning my on switch, voltage goes from 81.7 up to 92.3V and hovers there...

So something is funky w/ CA. .

I had that happen to me when I upped my voltage to around 86V (hot). It appears that some of the CA's have a problem with a resistor popping over 72V. It's a surface mounted one and I didn't want to attempt to switch out. Get in touch with Justin. He will take care of it. (ebikes.ca is #1)

[GCinDC]

Thing is, I've had the CA running perfect with my (used to be YOUR) 846 controller!

I just posted to the E-Bike Technical forum: Proper Wiring of the CA/EBrake to 116 Controller (BLP7245)?

On my 846 controller, I've got two wires going to the bottom of the shunt and one to the top! The 116 has two to GND on the edge...

I probably shouldn't do this, but just so I have everything together for myself, I'll republish it:

New controller issues...

I've just swapped my 846 infineon controller with a 116, bought directly from Keywin/ecrazyman, in an attempt to get higher regen. (for braking, not nec for charging...)

So first, I've performed the following mods on the 116 out of the box from Keywin:

-> jumped BK/GND (acutally put them on a switch)
-> removed R12 and soldered in 1K ohm resistor
-> soldered programming header to board (and programmed board with these settings)
-> added power switch, or attempted to.... The power lead connector had three wires: two thick +/GND wires and a thin red + wire attached to Vcc-1.
I assumed the thin + wire was for a switch so I wired it like my 846 controller is wired: with a switch on the thin + wire from Vcc before it enters the + powerpole terminal. (as in the diagram below). Not sure what mate there should have been for this on the battery side...

So, the issues:

__ 1. When I turn on the switch (which I ran to the handlebar), the CA Voltage reads a steady 82V for 15-45 seconds, and THEN it shoots up to 93V and oscillates there, within a volt or two. Somewhat disconcerting, having lipos & all... but obviously there's no change in battery voltage. This is w/ bike at standstill, no throttle at all. I've tried timing it, but timing isn't consistent. Seems to occur sooner after depressing eBrake...

Fullscreen capture 1242010 124202 PM.jpg (90.61 KiB) Viewed 1362 times

__ 2. The eBrake lever, when depressed, causes the CA to display only backlighting, no more characters, and have no effect on braking. The eBrake line, (YEL/BLK from controller) isn't wired to EBS, as on 846 controller. Here are some shots from top (L) and bottom (R). Is this correct??

Fullscreen capture 1242010 12749 PM.jpg (99.8 KiB) Viewed 1363 times

Any suggestions!?

My build thread here. Issues mentioned in last post, p. 5.

Thanks

[GCinDC]

PS. and oh yeah, another big diff between my 846 and 116 controller is:

When I plug in the power leads (andersons) on the 846, I get NO SPARK
When I plug in the power leads (andersons) on the 116, I get MOTHER SPARK... This I'd like to CHANGE!

[dbaker]

I know what you mean about sparking! With my 24s pack and the 18fet infineon I get major sparking and even on just the ignition wire (S). The technical area has this thread on the subject:

http://endless-sphere.com/forums/viewtopic.php?f=16&t=7994


Summarizing, you need to use a series resistor to reduce the capacitor charging current. These is a link to a tool in the thread for sizing that resistor. I plan to use a SPDT switch for my (S) wire that will place a series resistor on one of the switch positions. To operate I will switch from center off to resistor pole for a minute or so and then switch to the straight through position.

Dave

[Mark_A_W]

My solution is to use a 50A Anderson connector. The grey one with two integrated connectors.


The spark erodes the front end of the conductor, which does not actually contact when the connector is fully connected - so it doesn't matter. And the spark is miles away from your fingers.

Also, the conductor is huge, so the spark damage would take YEARS to render it useless.


Every few months I clean up the front of the conductor with a small file.

[GCinDC]

Thanks guys. Great ideas. I've started connecting them slower, letting the spark happen and then it slides in fine, basically destroying the tip only. But the resistor bmethod should be easy enough, once I get the proper resistor...

Dave, you shouldn't need to disconnect though, right? Since you're going cc cv... not sure I understand the switch idea. You connect while switch off. Then switch pos one charges caps, and then pos 2 won't spark? Get the parts. I'll come by this weekend!

Dave's making a mean machine!

[GCinDC]

I plan to use a SPDT switch for my (S) wire that will place a series resistor on one of the switch positions. To operate I will switch from center off to resistor pole for a minute or so and then switch to the straight through position.

Will two poles of the switch have 10 guage wire, and will all that current be passing through the switch?

I see how the switch can be used to avoid the spark, but it has to also allow the current to pass too, in the second position, no? In which case it would have to be rated for all that, right?

Just found an old post of mine where everyone laughed at my switch.

[etard]

GC,
You have to get a video posted of that commute. I remember going to college riding down Rock Creek to Georgetown messing about on bikes and hucking around The Mall with my buddies. Ah, good times . Anyway, I would love to watch your morning commute, always wanted to be a bike currier. I also used to have a GT Idrive frame, never built it up as intended, never had faith in the seatpost design. Mine was actually cracked and repaired rather poorly. But the ones that don't break seemed to be an immensely good ride. Watch out for the GT in DC!!

[GCinDC]

You have to get a video posted of that commute....

etard, i love your avatar name!

thanks for encouragement. you inspired me:

2010-01-28 08.15.06 (1).jpg (157.15 KiB) Viewed 1243 times

i need to borrow someone's usb cable to post the vid. the mount held up okay, though a helmet mount would certainly be better. i was surprised the video stayed as stable as it did - must be the effect of the fish eye (gorilla taped to front of camera).

unfortunately, my memory card ran out after 6 minutes, but that's fine since youtube only allows 10 min, right?

I'll post other vids downtown later. meanwhile, stay tuned for part one, NW DC -> Just past (observatory) VP's house on Mass.

[GCinDC]

[bzhwindtalker]

I like how you take STOPs

[etard]

First of all let me say:

You have just reached legendary status in my book!! Splitting lanes like that, you belong in CA man, you can do that legal on motorcycle ( or ebike). Looks like NW with all the colonial brick houses, kinda like Chevy Chase. I love it, miss that area, not the cold weather, but there is so much culture and great architecture. Your bike seems very fast, what was your top speed? You should post the other half on your way home. One more thing, I can't believe you jump curbs with that camera gorrila mounted! My family lives in the Shenandoah Valley, and my best friend is in Takoma Park, so we might have to meet up sometime.

Might I suggest one of these: http://www.jensonusa.com/store/product/ ... lebar.aspx

[GCinDC]

Thanks! Glad you liked it...

Stay tuned for more!!

Might be time to create a new youtube channel. Right now I've got the vid in with all the new baby vids... The grandparents are subscribed so I might be getting some calls after they watch it.

what was your top speed? ... I can't believe you jump curbs with that camera gorrila mounted! My family lives in the Shenandoah Valley, and my best friend is in Takoma Park, so we might have to meet up sometime.

Tippedy-top speed on the bike is 40mph. On that ride, I probably hit 35 on that bumpy stretch I was side-by-side w/ the white car.

Re the gorilla mount, the camera is actually screwed tight to a mini-tripoed which is velcroed once around head-tube, and taped around it twice... I was surprised it didn't bob down though.

Drop me a line when you're back in town! I still want to set up an ebike club in the metro area...

[greenerwheels]

Sweet!........... I mean, that's not responsible riding and does not reflect well on the overall electric bike movement ................ Yeah well.........its Still......... Sweet!!! You have larger Nads than I, here in Portland ("self proclaimed bike capital of the universe") Someone would open a car door on you and then a judge would make you pay to repair the guys car door. Of course speed can be used to an advantage, you're gone before anyone realized you were there. be safe. And thanks for video of your splendid ride!!!

Greenerwheels

[amberwolf]

They sure don't waste paint on lane markers, do they? I wasn't even sure there *were* separate lanes on the road for a minute or two.

[biohazardman]

Not responsible, not courteous and downright dangerous riding that is! Still you can ride and a great video you made. I was once invincible myself but then the kids came and I became very mortal. Think I will send the vid to my kids and tell them it's me. ;^) I hope that you don't ride like that all the time wish all our politicians would though. ;^) Thanks for the vid.

[Mark_A_W]

Kinda reminds me of me....except it's all backwards and the only cars I recognise are subarus..and it looks cold. Your bike is faster!



I took a stop sign like that the other day...right in front of a cop car. They didn't care

[full-throttle]

Great video!!

Took you a while to pass that mini

[GCinDC]

[icecube57]

Thats just freakin Awesome!

[dbaker]

I completely forgot what I was going to say about the switch! I can see now why you say the commute is the best part of your day! How hot does that 9C get at the end of the ride? Is your pack pretty much depleted by the time you get there? You had already towed the kids to daycare before the video started and that has to take some of the pack.

WOW! Awesome ride! Did you drive the same way when you were on the hardtail with the front motor? I am not seeing much need for regen. What were there 5 or 6 stops?

Back to the switch! With the 18fet controller I was finding a lot of inrush current with my master switch (it is only supposed to provide power to the controller logic) so much so it fried the first switch I used. I could hear sparking inside the switch when it was turned on. I used the resistor calculator and it suggested a 500 ohm 5 watt resistor. I used two 2 watt 1k ohm resistors in parallel and it seems to work fine. I use a SPDT switch to initially close the controller logic circuit in series with my 500 ohm resistor and then after a pause switch to the other pole to go direct from B+ to the controller logic. I will eventually rig up another series resistor to use for making the battery connections if I commute with the bike. I just managed with the Andersons like Mark said with my previous LiFePO pack. Going to 24s and the 18 fet controller gives a plasma discharge when I connect the battery to the bike that is too hard on the connectors. After watching your video and seeing the performance I think it is too much for the bike trail. For my commute at 5:45am I will have to upgrade my lighting to go 35mph. Hitting a deer would really hurt! Got to try it out for sure. Might be a little longer if we get snow tomorrow?

Maybe we can look at the controllers this weekend? Was that ride on the new controller with the new regen settings?

Dave

[johnrobholmes]

What a nice build! Looks like you ride the snot out of that. Keep an eye on the upper shock bolts (frame). I had two of those frames and it was a frequent breakage point.


Thanks for sharing the vid, much enjoyed!

[GCinDC]

Thanks for your comments! And in case you were wondering, I'm NOT in politics...

Regarding SAFETY:
- Yes, I was taking more risks than 'normal'; I don't always go through traffic that fast.
- The fisheye lens distorts the view of the distance; I can see much more, and further
- I know the road by heart!
- I cut my handlebars down 30mm each side to make it easier to go between cars
- Now you can see how excited I was to get full suspension; w/o it on those roads w/ my comfort bike was getting dangerous
- Full-face helmet in case of the worst

Oh, and since the baby arrived, grandma's been in town and taking the kids to school. In a couple weeks, I'll be towing the kids again in the trailer for the first mile of the commute.

There were a couple other things to mention but I forgot.

[liveforphysics]

WOW! Great commute video! That looks like it's likely the fastest option for travel in your city. Great job building your fast bike!