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[Doctorbass]

It is official, my old 2012 ZF9 is now using the SR size 6 controller as well as the 75-7 motor of all 2013+    ... Oh.. and with boostpack to bring it to ZF15!

ONe of the most complicated part was to rebuild the DCF file for the controller  that match all these parameters together from other  DCf files from the 2014 SR, 2012 S with 75-7 motor.

I have used Winmerge and isolated every single variable that a reuncommon to both files from the 2014 SR and 2012 S 75-7.

for exemple, setting the new torque to 180Nm, new max current 660A insteaf of 420, etc

I have preserved all voltage parameters from the 2012 S file to keep all  compatible settings that are made for the 66V battery of teh 2012 and have transfered all  parametres like torque, current, gain, torque curves etc...

After couple hours i finaly got the file and tested it.... and IT WORKED !! .. Well with the bike on the stand  the rear wheel spin no prob and is very fast!!!.. but not tested yet on the road, it's 1am now and it's -3 degree outdoor with ice  on road at some place!!! ...

I'm watching carefully mother nature predictions so i can test it fully!

btw just by holding the rear brake to apply torque i twisted teh throttle and saw  35.5kW already and was not full torqu and speed yet !! and battery was at 66V...

I call this encouraging!!!!



I have attached it for you guys!

[Doctorbass]

here it is!

Doc

[Justin Andrews]

Excellent work!

[Burton]

And now ... time for a clutch engine "foot brake" lol Once you use one you won't want to go back ...

If you are interested find the thread or two here talking about setting it up and if you need more assistance just PM me and I can answer any questions you might have

[Doctorbass]

Great , thanks for the offer Burton!

I think i saw these post. Arlo also built one using strain gauge on the brake handle.

Doc

[Cortezdtv]

I love watching people hack bikes

Good work!!!

Did you end up replacing the harness and:or repopulate sevcon plug  and/ or your 2012 had the size 2 or 4 from the beginning?

Did you then use a MY 13plus bms?


I would think you went to MY 14.   But awaiting new response!!!


Like I said good work!!!! No too many people decided sevcon to re-parameter for a different bike!!!   


So I take it you now have a badass SR!!!! Now that you have a zf15 turn the controller up lol (shame your not at the 100v at zf15). 100+ foot lbs and some serious go would be coming your way

[eyeinsky]

Great Job Doc! was there ever a doubt? I'm in YUL now this morning -5 So you better get it out soon winter is here...LOL Halifax was still above 0 this morning...

Cheers Jerry

[Lecram]

Good job, great project!

[Doctorbass]

I love watching people hack bikes

Good work!!!

Did you end up replacing the harness and:or repopulate sevcon plug  and/ or your 2012 had the size 2 or 4 from the beginning?

Did you then use a MY 13plus bms?


I would think you went to MY 14.   But awaiting new response!!!


Like I said good work!!!! No too many people decided sevcon to re-parameter for a different bike!!!   


So I take it you now have a badass SR!!!! Now that you have a zf15 turn the controller up lol (shame your not at the 100v at zf15). 100+ foot lbs and some serious go would be coming your way

No need to replace the harness as i'm still using the 2012 battery of 66V and the stock MBB  and BMS too. I only needed to swap the IN/COS encoder wires due to the motor installed on the right on the 2012 and not on the left so it have to spin backward.

The actual 6p 120Ah of eig cells can take burst of 10C and continuous 5C witch is 600 Acontinuous and 1200A burst. so what really limit is the fuse!.. it is an internal 425A i the battery an dthe new size 6 also have a 425A fuse. The old size 4 controller it had a 355A fuse.

Doc

[Doctorbass]

Btw thanks for all apprecaitions guys!. i'm very impatient to try it on the road.. I just need a great weather!

Doc

[benswing]

We may be able to go on a bit of a road trip together next summer because I'll have a diginow super charger!   Looking forward to your ride reports.


Sent from my iPhone using Tapatalk

[Doctorbass]

We may be able to go on a bit of a road trip together next summer because I'll have a diginow super charger!   Looking forward to your ride reports.


Sent from my iPhone using Tapatalk

Hey ben, excellent new!.. Ah next summer!!.. so many snow flake from there!!!

[Doctorbass]

Tested today!!

WOW.. Awsome brutale acceleration!!!

In fact i have the same as teh SR does but not the same powerband, meaning myne with oly 66V battery can not sustain that torque as far in RPM as the 2013+ does.

But believe me.. for the 0-80km/h that is AWSOME!!

I will rework a bit the Torque vs RPM curve in the DCF to try extending further the torque in higher RPM.

I measured 592A battery current from now at 65V witch mean about 38kW..  I woudl say about 34kW at the wheel meaning about 42hp.. but there is still margin to tweak a little bit the parameters and get as high as 660A or more on the battery side =)

Doc

[ColoPaul]

Awesome Doc.  Really!   I wish you'd put together a "how-to" instruction list, and I'd do the same on my 2012.

Why did you keep your pack voltage at 2012 levels?

[Doctorbass]

Awesome Doc.  Really!   I wish you'd put together a "how-to" instruction list, and I'd do the same on my 2012.

Why did you keep your pack voltage at 2012 levels?

Well that's less complicated actually this way. the 2016 pack is made of 3 brick of 18s2p and BMs work only for 18s.

To modify the battery i would have to rebuild the battery configuration to 28s, replace the actual BMS and MBB and DC-DC, but the most complicated would be to make 28s and enough p to keep the same kWh.

Actually this is 36 cells x 3 = 108 cells and now divided by 28s mean 3.86.. so ideally i would need 4p and get some cells that have about the same age as mine to keep the pack excellent balancing job. this mena i would need 4 x 28s = 112s. and i would get 80Ah at 102V nominal instead of 120Ah at 66V.

That would be enough for powering the size 6 for 660A burst for sure as the EIG cells are capable of 5C cont and 10C burst so 800A burst wold not be a problemf or the 660A request from the controller.

But the other problem is that i already built two range extender battery pack made also for 18s.. so i would need to reconfigure these for 28s and the case only have the room for 36 cells each,  so i would need to decrease the number of cell to match the 28s... i can not raise to 56s in each case because ther eis not enough room and only using 28s  would make me loosing some kWh of storage...

Doc