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  1. BlackburnPete

    A123 Pouch Cell Failure?

    Happy to report that OSN Power sent me a new A123 pouch cell (20Ah) and I opened up the pack. I immediately saw a leaking corner on the third cell in from the positive end of the pack. I suspect some kind of physical failure, but the pack was very well protected in a padded plastic ammo box...
  2. BlackburnPete

    A123 Pouch Cell Failure?

    Thanks fechter, I have disconnected the BMS and I have a single cell charger. I am still trying to figure out a suitable load for a single cell discharge without buying a CBA IV from westcoastmountain.com. Any ideas? Something safe ;-)
  3. BlackburnPete

    A123 Pouch Cell Failure?

    Thanks Agnuism for the kind offer.I have a new cell coming already. Please PM me with your offer including shipping to Ottawa, Canada. I will probably need to start replacing cells on this pack now that one is showing signs of trouble. I have had some temporary success by replacing cells in a...
  4. BlackburnPete

    A123 Pouch Cell Failure?

    The pack was from OSN Power (2013) and it is 16 pouch packs with bolt on connectors. The foil connectors are folded under the metal strips.
  5. BlackburnPete

    A123 Pouch Cell Failure?

    Today, all cells are sitting at 3.35 still except that one cell is now sitting at 3.2V. Do you think I should I should replace that cell? How can I test it to see if it is faulty?
  6. BlackburnPete

    A123 Pouch Cell Failure?

    I just noticed my battery charger was going on and off every couple of seconds. I have a 16S1P A123 LiFePO4 pouch battery pack that has been working flawlessly since of 2013. I have a Kingpan 5A charger that always charges my pack to 58V. After shutting down the charger, I checked the overall...
  7. BlackburnPete

    BMC gear-drive motor won't restart

    I just checked the voltage on the hall sensor wires, I disconnected the green controller hall wire from the yellow motor hall and put an alligator clip from my digital multi-meter on each wire and carefully rotated the motor backwards until it registered 13.5 volts with the controller turned on...
  8. BlackburnPete

    BMC gear-drive motor won't restart

    The halls and phase wires are currently set up as per the link in teklektik's previous post and the combination spins up the motor from a standstill. If I hold the throttle on, the wheel keeps turning under the motor power, but once I back off the throttle, the motor will not restart. Very...
  9. BlackburnPete

    BMC gear-drive motor won't restart

    I already have the wires bare from the motor and controller side. I have been twisting them together and using small blue marrette screw-on connectors to keep them tidy until a final solution. I have the tools and parts to replace the Anderson connectors for the phase wires and I have the...
  10. BlackburnPete

    BMC gear-drive motor won't restart

    Yes, I picked up the parts used, but the old Crystayte controller is supposed to be the one that works for this BMC motor. It was part of a working bike project, but I never saw the old project in action. The controller is a Crystalyte with a red push button power switch. The controller's hall...
  11. BlackburnPete

    BMC gear-drive motor won't restart

    Thanks teklektik, your explanation of the heat causing the problem is very convincing. This motor is very loud right now. Would an incorrect hall /phase wire combination lead to unnecessary heat and noise? The symptoms occur even on the bench with no load on the motor, just free spinning in the...
  12. BlackburnPete

    BMC gear-drive motor won't restart

    I have a BMC hub motor in the front wheel of a cruiser bike. The wheel will start and run as long as there is power applied by the throttle. However, after coasting, the motor will not respond again until it comes to a complete stop and rests for a few minutes. To isolate the issue, I changed...
  13. BlackburnPete

    Kingpan KP-669 110V or 220V?

    I tried to upload the pictures, but I will need to shrink them down to 512kb first. Can I plug this charger into the stove or dryer plug if I change the plug?
  14. BlackburnPete

    Kingpan KP-669 110V or 220V?

    I have been given a V-Power KP-669 charger that is 'repairable'. The charger even came with the part to replace and some advice on doing the job. However, the charger appears to be a 220V charger and I live on a 110V continent. The label on the back of the charger has a lot of Chinese characters...
  15. BlackburnPete

    Swap Crystalyte 404 guts to 405 hub?

    Both are front motors. I will verfy that the side covers have the same bolt patern before I begin. I am waiting to borrow a big puller to avoid damage to myself and the motors. I've heard some people can pull them by hand, but I am cautious. Ypedal, do you use a puller to get them apart? Is...
  16. BlackburnPete

    Swap Crystalyte 404 guts to 405 hub?

    Thanks Ypedal, Will I have to remove the Andersons on the phase wires to get them through the side cover? Will the five pin connector for the Hall sensor wires fit through?
  17. BlackburnPete

    Swap Crystalyte 404 guts to 405 hub?

    I have a Crystalyte 404 with a 16 inch (305) 28 hole rim and I also have a Crystalyte 405 with a 20 inch (406) 36 hole rim. I want to pull the windings and wiring from the 404 hub and put them into the 405 hub body and then re-install the guts from the 405 back into the 404 hub body. This will...
  18. BlackburnPete

    Noisy powerless motor

    After re-installing the BMS and charging up the pack, all the lights come on except the string that was recently replaced. The charger shuts down and then the second string LED (next to string #1 that new) blinks a few times and then goes out. The remaining 14 LEDs are still lit. I have left it...
  19. BlackburnPete

    Noisy powerless motor

    Battery works fine without the BMS. I was keeping the amperage down to 15-17A and running most of the time around 9-10A. The pack maintains 52.8V resting and drops to 51.2 -51.5V under 10-15A load. I burned up and down my block a few times and pulled 1.67Ah fom my pack at 16 Wh/km. I reconnected...
  20. BlackburnPete

    Noisy powerless motor

    I am using CycleAnalyst to limit the Ampeage draw to 25A and if the Ping BMS shuts down the pack, I have to unplug it from the controller and plug it in again to reset the BMS, but no reset is necessary. If I try it without the BMS, it should roll smoothly if the BMS is indeed shutting it off...
  21. BlackburnPete

    Noisy powerless motor

    I have a Crystalyte 404 motor coupled to an Infinion 35A controller that works flawlessly with my 48V 20Ah A123 pack, but when I put my 15Ah Ping pack on the bike, my motor runs extremely rough and noisy and has no power to move the bike. I must admit the Ping pack is old and repaired but stll...
  22. BlackburnPete

    convert a 48 volt battery

    Why not just buy a 48V to 12V DC to DC converter? No need to do anything to the pack. I used one to power an inverter for decorative lighting on my bike.
  23. BlackburnPete

    Henry111's free tech support thread

    Try a plastic ammo box like the one listed here: http://www.sail.ca/en/catalogue/hunting/accessories/?page=3 The ATV Dry Box comes with a plastic tray that can be zip-tied to a bike rack. Then the box can be bungied or strapped into the tray. I have two of these set up now. Waterproof, tough...
  24. BlackburnPete

    LiFePO4 Charger Output Voltage

    Recently, I purchased a 48V 20 Ah A123 LiFePO4 battery pack from OSN Power. I haven't used it yet. This pack is replacing my Ping 48V 20Ah pack made from 16S4P pouch cells. When my Ping pack died and my new pack arrived, I figured that I would just use the charger that came with my Ping pack. It...
  25. BlackburnPete

    Nee suggestion for new bike rack

    I had 48V 20Ah of LiFePO4 (32 lbs duct-tape pack) in a tuuperware tub mounted on the PDW Payload rack. Here is the link. http://www.ridepdw.com/goods/cargo/payload%E2%84%A2 The wooden deck makes it easy to mount the battery box.
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