Difference between revisions of "RAD Mod - External Battery"

Revision as of 18:06, 26 May 2018

This is a tutorial for an ADVANCED MOD where an external battery is connected, bypassing the onboard battery pack.

This modification includes soldering, drilling, and harness building. Previous experience in these areas is recommended/required.

The overall concept is to set up a wiring harness to allow switching between the onboard battery and a larger external battery for greatly extended range and increased performance.

Pros and Cons

Pros	Cons
Allows for customized range	Warranty is done done done
More cells in parallel exhibit lower voltage drop and can output more continuous power	Battery compartment must be opened
Can be implemented to correct issues with the stock BMS or the stock battery	Drilling/soldering required
Nothing hanging out of your charge port. Setup is more robust, less prone to accidental damage.	Loss of amp measuring and cell voltage (see BMS bypass note)
Preserves Original Battery	Loss of cell balancing
Onboard battery and external battery can be charged through chargeport.
Switch back and forth between onboard battery and external battery for "naked riding" and long range cruising
Bypassing BMS means no accidental shut-offs, regen warnings, and other BMS associated issues
Compatible with all OW versions (different battery pack setups may be necessary for optimal results)

Parts List

This is meant to be a suggested parts list rather than a specific build of materials. Components can be replaced based on user requirements/preferences.

XT90S Connectors: These antispark connectors will precharge the controller instead of slamming them with the full 58v upon connection of the harness. This is recommended to prevent any damage to the control module. A separate precharge resistor circuit can be hooked up beforehand if alternate connectors are desired.

https://www.amazon.com/gp/product/B0732S5V85/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1

Adhesive Heat-shrink:

https://www.amazon.com/gp/product/B01N6EFUKR/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

Grommet: Used to secure the wires travelling through the battery case

https://www.lowes.com/pd/Hillman-2-Pack-0-625-in-Rubber-Grommet/3013196

14AWG Wire (Black and Red)

https://www.homedepot.com/p/Cerrowire-25-ft-14-Gauge-Single-Conductor-Black-Stranded-THHN-Wire-112-3401A/202564770

Battery Pack

Similar to the CnR mod or the charging on the go setup, a battery pack must be sourced for this application. The goal here is to match the voltage of the existing battery.

In order to get the full advantage of the RAD mod, it is recommended to use a battery with more than one set of parallel cells. This shares the load between the cells and increases the overall performance (by reducing voltage drop).

Each parallel set of cells is roughly equivalent to 7-miles range, or similar to whatever range you were getting on the OW+

Options:

1) LiFePO4 (same chemistry as original battery) Nominal cell range 3.0-3.62v/cell or 48V Empty, 58V full.

Specs: 16s1p or greater.

2) Li-ion (18650 ebike style packs or pouch-style packs) Nominal cell range 3.6v-4.2v/cell or 50.4V Empty, 58.8V full.

Specs: 14s1p or greater

Conclusion: Allthough there are benefits to using the A123 LiFePO4 cells, it is the opinion of the tutorial creater that the Li-ion pack has a more favorable nominal pack voltage window (slightly better performance in most situations) and is ultimately similar in safety. The availability of Li-ion cells is also an advantage.

Nominal pack voltage window:

Charging

Charging can be done in several ways.

1) External charger: There are a number of 14S chargers out there for the Ego battery packs and similar ebikes. YMMV with the charge rates and full voltage settings.

It is highly recommended to limit full voltage to 57v if no BMS or balancing solution is being used. Similarly, it is recommended not to fully discharge your battery if there is no LVC cutoff/alarm.

The highest quality, fully programmable charger is the Cycle Satiator http://www.ebikes.ca/product-info/cycle-satiator.html

2) Stock charger: Although extremely slow for charging a big pack, the stock charger or "Carve-Power" style charger can be used through the XLR charge port, as long as the battery is plugged in and the board is on.

Assembly

BMS Bypass

The BMS bypass can be used in combination with the RAD mod or it can be used alone.

The reasons for eliminating the BMS:

BMS has failed or is inaccurately reading cell voltages and shutting off the board.
Removes the ability for the BMS to cut power to the controller under any circumcstances (good or bad.
- Note: The controller will still shut off the board when the voltage drops too low. It is highly recommended to avoid this situation.

Category:

@@ Line 20: / Line 20: @@
 |-
 |Nothing hanging out of your charge port.  Setup is more robust, less prone to accidental damage.
-|Loss of amp measuring and cell voltage view (see BMS bypass note)
+|Loss of amp measuring and cell voltage (see BMS bypass note)
 |-
-|Preser
+|Preserves Original Battery
+|Loss of cell balancing
+|-
+|Onboard battery and external battery can be charged through chargeport.
+|
+|-
+|Switch back and forth between onboard battery and external battery for "naked riding" and long range cruising
+|
+|-
+|Bypassing BMS means no accidental shut-offs, regen warnings, and other BMS associated issues
+|
+|-
+|Compatible with all OW versions (different battery pack setups may be necessary for optimal results)
+|
 |}
-external battery can be charged through chargeport.Switch back and forth between onboard battery and external battery for "naked riding" and long range cruisingBypassing BMS means no accidental shut-offs, regen warnings, and other BMS associated issuesCompatible with all OW versions (different battery pack setups may be necessary for optimal results)It's impossible for a defective footpad to cause a run-away board when using a backpack battery.Parts ListThis is meant to be a suggested parts list rather than a specific build of materials. Components can be replaced based on user requirements/preferences.XT90S Connectors: These antispark connectors will precharge the controller instead of slamming them with the full 58v upon connection of the harness. This is recommended to prevent any damage to the control module. A separate precharge resistor circuit can be hooked up beforehand if alternate connectors are desired.<nowiki>https://www.amazon.com/gp/product/B0732S5V85/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1Adhesive</nowiki> Heat-shrink:<nowiki>https://www.amazon.com/gp/product/B01N6EFUKR/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1Grommet</nowiki>: Used to secure the wires travelling through the battery case[https://www.amazon.com/gp/product/B01N6EFUKR/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1 https://www.lowes.com/pd/Hillman-2-Pack-0-625-in-Rubber-Grommet/3013196]14AWG Wire (Black and Red)<nowiki>https://www.homedepot.com/p/Cerrowire-25-ft-14-Gauge-Single-Conductor-Black-Stranded-THHN-Wire-112-3401A/202564770Battery</nowiki> PackSimilar to the CnR mod or the charging on the go setup, a battery pack must be sourced for this application. The goal here is to match the voltage of the existing battery.In order to get the full advantage of the RAD mod, it is recommended to use a battery with more than one set of parallel cells. This shares the load between the cells and increases the overall performance (by reducing voltage drop).Each parallel set of cells is roughly equivalent to 7-miles range, or similar to whatever range you were getting on the OW+Options:1) LiFePO4 (same chemistry as original battery)  Nominal cell range 3.0-3.62v/cell or 48V Empty, 58V full.Specs: 16s1p or greater.2) Li-ion (18650 ebike style packs or pouch-style packs) Nominal cell range 3.6v-4.2v/cell or 50.4V Empty, 58.8V full.Specs: 14s1p or greaterConclusion: Allthough there are benefits to using the A123 LiFePO4 cells, it is the opinion of the tutorial poster that the Li-ion pack has a more favorable nominal pack voltage window (slightly better performance in most situations) and is ultimately similar in safety.  The availability of Li-ion cells/chargers is also an advantage.Nominal pack voltage window:ChargingCharging can be done in several ways.1) External charger:  There are a number of 14S chargers out there for the Ego battery packs and similar ebikes. YMMV with the charge rates and full voltage settings.It is highly recommended to limit full voltage to 57v if no BMS or balancing solution is being used. Similarly, it is recommended not to fully discharge your battery if there is no LVC cutoff/alarm.The highest quality, fully programmable charger is the Cycle Satiator '''<nowiki>http://www.ebikes.ca/product-info/cycle-satiator.html</nowiki>'''2) Stock charger: Although extremely slow for charging a big pack, the stock charger or "Carve-Power" style charger can be used through the XLR charge port, as long as the battery is plugged in and the board is on.AssemblyBMS BypassThe BMS bypass can be used in combination with the RAD mod or it can be used alone.The reasons for eliminating the BMS:BMS has failed or is inaccurately reading cell voltages and shutting off the board.Removes the ability for the BMS to cut power to the controller under any circumcstances (good or ba
+== Parts List ==
+This is meant to be a suggested parts list rather than a specific build of materials. Components can be replaced based on user requirements/preferences.
+XT90S Connectors: These antispark connectors will precharge the controller instead of slamming them with the full 58v upon connection of the harness. This is recommended to prevent any damage to the control module. A separate precharge resistor circuit can be hooked up beforehand if alternate connectors are desired.
+https://www.amazon.com/gp/product/B0732S5V85/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1
+Adhesive Heat-shrink:
+https://www.amazon.com/gp/product/B01N6EFUKR/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1
+Grommet: Used to secure the wires travelling through the battery case
+https://www.lowes.com/pd/Hillman-2-Pack-0-625-in-Rubber-Grommet/3013196
+AWG Wire (Black and Red)
+https://www.homedepot.com/p/Cerrowire-25-ft-14-Gauge-Single-Conductor-Black-Stranded-THHN-Wire-112-3401A/202564770
+== Battery Pack ==
+Similar to the CnR mod or the charging on the go setup, a battery pack must be sourced for this application. The goal here is to match the voltage of the existing battery.
+In order to get the full advantage of the RAD mod, it is recommended to use a battery with more than one set of parallel cells. This shares the load between the cells and increases the overall performance (by reducing voltage drop).
+Each parallel set of cells is roughly equivalent to 7-miles range, or similar to whatever range you were getting on the OW+
+'''Options:'''
+) LiFePO4 (same chemistry as original battery)  Nominal cell range 3.0-3.62v/cell or 48V Empty, 58V full.
+Specs: 16s1p or greater.
+) Li-ion (18650 ebike style packs or pouch-style packs) Nominal cell range 3.6v-4.2v/cell or 50.4V Empty, 58.8V full.
+Specs: 14s1p or greater
+'''Conclusion:''' Allthough there are benefits to using the A123 LiFePO4 cells, it is the opinion of the tutorial creater that the Li-ion pack has a more favorable nominal pack voltage window (slightly better performance in most situations) and is ultimately similar in safety.  The availability of Li-ion cells is also an advantage.
+'''Nominal pack voltage window:'''
+== Charging ==
+Charging can be done in several ways.
+) External charger:  There are a number of 14S chargers out there for the Ego battery packs and similar ebikes. YMMV with the charge rates and full voltage settings.
+'''It is highly recommended to limit full voltage to 57v if no BMS or balancing solution is being used. Similarly, it is recommended not to fully discharge your battery if there is no LVC cutoff/alarm.'''
+The highest quality, fully programmable charger is the Cycle Satiator http://www.ebikes.ca/product-info/cycle-satiator.html
+) Stock charger: Although extremely slow for charging a big pack, the stock charger or "Carve-Power" style charger can be used through the XLR charge port, as long as the battery is plugged in and the board is on.
+== Assembly ==
+== BMS Bypass ==
+The BMS bypass can be used in combination with the RAD mod or it can be used alone.
+The reasons for eliminating the BMS:
 * BMS has failed or is inaccurately reading cell voltages and shutting off the board.
-* Removes the ability for the BMS to cut power to the controller under any circumcstances (good or ba)d.
+* Removes the ability for the BMS to cut power to the controller under any circumcstances (good or bad.
 ** Note: The controller will still shut off the board when the voltage drops too low.  '''It is highly recommended to avoid this situation.'''
 Category:
 [[Category:Mods|Mods]]