Building an EV motorcycle. Batteries: Need opinions.

[Daox]

Do you have any pictures of your build? We'd love to see them.

[TurnNBurn]

Originally Posted by Daox

Do you have any pictures of your build? We'd love to see them.

I don't have any recent ones, but I'm going to re-adjust and tighten the rear wheel today or tomorrow and I'll get some pictures then. Right now it's just the frame with the sprocket and motor mounted. I haven't mounted the controller yet because I don't know how much space the batteries will take up. I plan on putting the controller either under/behind the seat of the rider or where the gas tank used to be.

[Daox]

Take some pics and we can give you some suggestions.

[TurnNBurn]

You can see the tiny batteries I'm using at the bottom of two pictures. 12 volts each, about 7 ah. Only 3 of the 4 batteries work. But I got it rolling with 36 volts tonight. No throttle grip. I haven't wired up the controller yet.

So now I'm about to wire the throttle and controller just to test it out, but I want to use the same proper wire. Where to the gauges come in handy? I was thinking 3 ga wire for the controller/battery connections. Is that too much?

Also, I went to Lowes looking for some wire terminals for the throttle group. What terminal sizes will work with the Alltrax 7245? Am I even using the right terminology?

I did a test and hooked up the controller and throttle and I couldn't get it to work. No light on the Alltrax LED. I had it hooked up to a good 12v battery. Any ideas?







And a video of it running here:

https://www.dropbox.com/s/ys0cc58f1v...225557_575.mp4

I believe that's only 24v it's running on.

[TurnNBurn]

UPDATE

I'm still having issues with the controller. Could it be bad? Or just my wiring sucks?

Also, I lucked out and found a local vendor of Nissan Leaf batteries. The website says:

"11 KW/h 182V / 60Ah packs for $2520 - connected with harness.
1.8kW/h / 30.4V / 60Ah - $470 - connected with harness.
3.6kW/h 60.8V / 60Ah- $880 - connected with harness."

Will two of the 3.6kW/h 60.8V packs get me the same range as 24 60Ah CALB batteries?

[Ryland]

Originally Posted by TurnNBurn

You can see the tiny batteries I'm using at the bottom of two pictures. 12 volts each, about 7 ah. Only 3 of the 4 batteries work. But I got it rolling with 36 volts tonight. No throttle grip. I haven't wired up the controller yet.

So now I'm about to wire the throttle and controller just to test it out, but I want to use the same proper wire. Where to the gauges come in handy? I was thinking 3 ga wire for the controller/battery connections. Is that too much?

No such thing as to large of wire.
American Wire Gauge table and AWG Electrical Current Load Limits with skin depth frequencies and wire breaking strength is one of the sites that I used, near the bottom they have a calculator.

Also, I went to Lowes looking for some wire terminals for the throttle group. What terminal sizes will work with the Alltrax 7245? Am I even using the right terminology?

Terminals or lugs, check at auto part stores, motor repair shops, or heavy truck repair shops that work on semi-trucks, the shop here that works on semi-trucks had crimpers and cable and were able to make everything for me, some auto part stores will make battery cables for you as well, other times they have stuck leignths that are already made up that are cheaper then buying bulk wire from them.

I did a test and hooked up the controller and throttle and I couldn't get it to work. No light on the Alltrax LED. I had it hooked up to a good 12v battery. Any ideas?
I believe that's only 24v it's running on.

What voltage do you have hooked up to the controller?
Alltrax AXE Products Page says you need 16v or more for the controller to turn on and it sounds like you hooked it up with just a single 12v battery.
They list wiring diagrams under their document section.

[TurnNBurn]

Originally Posted by Ryland

No such thing as to large of wire.
American Wire Gauge table and AWG Electrical Current Load Limits with skin depth frequencies and wire breaking strength is one of the sites that I used, near the bottom they have a calculator.


Terminals or lugs, check at auto part stores, motor repair shops, or heavy truck repair shops that work on semi-trucks, the shop here that works on semi-trucks had crimpers and cable and were able to make everything for me, some auto part stores will make battery cables for you as well, other times they have stuck leignths that are already made up that are cheaper then buying bulk wire from them.


What voltage do you have hooked up to the controller?
Alltrax AXE Products Page says you need 16v or more for the controller to turn on and it sounds like you hooked it up with just a single 12v battery.
They list wiring diagrams under their document section.

I reused some terminals I had from the UPS battery I got. I had quite a few I'm re-using. Got them cut and spliced to the throttle cables and they connect nicely to the controller.

As for the controller voltage....*FACEPALM* I read the wiring diagrams multiple times, but failed the most simple task of reading to find out what voltage it requires to turn on. I'll have to wire it again later to find out if it works. Right now the motor and mounting plate is off the bike because I'm going to finish it up and paint it to keep it safe from the elements.

I'm still in the process of sourcing some batteries. Funds are available I'm just looking for a vendor.

[P-hack]

Originally Posted by TurnNBurn

Will two of the 3.6kW/h 60.8V packs get me the same range as 24 60Ah CALB batteries?

7.2kwh vs 24*60*3.2=4.6kwh for the calb.

[TurnNBurn]

Does anyone know much about Nissan Leaf batteries and charging? The chemistry is not Lifepo4. They're LiMn2O4 with LiNiO2. How would one charge these batteries? I'm not finding much info on them.

[Giovanni LiCalsi]

EVTV Friday Show - January 10, 2014 - YouTube