72v BBSHD Upgrade: 3000W (Peak) ASI BAC Controller + 72v 15Ah 60A Battery + Display (NO Motor)
This is the fastest Off the shelf BBSHD solution in the world.
Higher Volts, Higher RPM Higher Speed !
This is truly plug n play and expect RELIABLE speeds of around 45+ MPH
choice of PAS levels with the 750c display
* UK Warranty
For international orders, please email: [email protected]
If you want to know the performance of this take a look: https://youtu.be/42Q6uEVNmwA
Ultimate BBSHD, battery and Controller Screen –complete kit with tft 750c Display and Gear Sensor motor cover all included!!
Did you ever wish your BBSHD went substantially faster, pulled harder and you didn’t have to be told you can’t buy the controller you want – shush it’s a secret?
Well thanks to a very clever friend of ours, we are the UK and EU distributor and co developer for this exceptional device.
Advanced processing and state of the art allows it to compute much faster and much more accurately than the standard Bafang unit (or any modded Bafang controller). Imagine your first media phone in comparison to the latest Iphone/Android device? – Things have moved on and these Canadian devices have not been designed with penny pinching mass market sales like the original. All of this makes your 52 V motor pull much harder and release around 15% more speed than a 50A Bafang controller and whopping 100% more power than the standard, while still using your standard display! (NB, please see our note about displays). We might add the power is designed to come in without the mechanical snapping lurch of an inferior set up.
These controller have been set up so that it can handle anything from 50 A up to 3000 W (easily within their design). This might mean a little explaining:
We have tested the BBSHD to destruction and on more than one occasion right up to 4500 Watts and learned a few things, real facts and not the odd exception.
Amps create heat, heat weakens the nylon gear and too many watts snap the pinion. So how do we get around this? Simple, know the limits but don’t get too close. Sure these are now nearer the limit, but ridden correctly (let the motor spin and don’t labour in the wrong gear), a reliable ride can still be had. At the lower volts where big amps are needed, we have capped the limit to 50A but as you increase your volts, we capped the watts to 3250 W. A ludicrous controller at 50A has 2500Watts – so does ours, but now add 10 -15% improvement through field weakening!
But here it gets even better, Change your battery and go up to 20s 72 V (any voltage form 10S to 20S, 36V -90 V) and the controller takes it (not a Bafang originated 60 V cap). Your watts have now jumped to a dangerous 4200 watts on a “hot” (fully charged battery at 84 V), so we reduce this limit to a safer 3000 W, but still so much powwweeeeer!
This is recommended as a throttle only and single speed (easy to adapt your free hub to single gears) application due to high RPM and low gearing. Your bike will accelerate like a rocket and still hit around 45 MPH, depending on how you gear your bike. You can accelerate faster or have a higher top speed. We find 45 MPH is enough. Bigger explanation further down.
Because of the weakness of the Nylon gear, the use of low gears is necessary and we recommend front 42T and rear no smaller that 28T on 29er or 27.5″ wheels and 26T on 26″ wheels.
We have tested this set up thoroughly with a 250 lb rider without issues.
No need for gear changes (although in low power mode this is still very usable with PAS) as the massive increased RPM range and large rear gear allows blistering acceleration and high top speed. Because of high voltage, low amps are used to obtain more watts. For example 72v x 50A = 3600 watts compared to 52v x 50A = 2600 watts. and we all know that high amps create motor killing heat, we limit the motor o 3000 w.
A 72V system uses less power and generates less heat but makes you go much faster.
The down side? = more money for the more advance controller (advanced field weakening) and the higher cell count battery. Because of the higher RPM a really good chain line is really important: drastically reduces wear and stops chains from snapping.
You no longer need other gears! your weedy legs are obsolete!!
We ship the controller with three power levels.
level 1 is around 1000w and hits speeds of around 30 mph with modest acceleration (similar to a standard BBSHD) and a range of around 30 miles
level 2 is around 1900w and hits speeds of around 40 mph with good acceleration and a range of around 20 miles 9 we tend use this setting all the time,as our main settings).
level 3 is full power and hits speeds in excess of 40 mph with blistering acceleration and a range of around 12-15 miles (we use this button like a Turbo, its too much for day in day out riding).
Order for USA (In stock no UK shipping) please go to: https://electroncycles.co.uk/product/asi-bac-800-36v-90v-foc-90a-peak-bbshd-hot-rod-controller-usa-orders/
Unfortunately not all displays are equal. Bafang released a myriad of display, and different firm wares. We are a small company and haven’t managed to test all of them; but what we have found, is that all the original displays still show everything (time, speed watts etc), but will not allow PAS or power selection. You can still ride your bike with the standard display on throttle only (please ensure you use low gears when running at full power or ask us to limit the power to 2500 watts, we do not recommend continuous full power as it may damage the Nylon gear or Rota shaft. Correct gearing must be used. – We highly recommend ramping power through the use of one of our display)
But, if you include the 750c display or a firmware updated Egg rider, that we list/supply, full PAS is restored.
How you budget your expectations and wallet is up to you. You can buy the kit without the display and see if perhaps your display gives PAS (we cant help here as there are too many combinations) and if not buy separately; or you can buy the kit with our display included and everything works.
Change of use (different motor or going 52v to up to 90v)
The controller is locked to protect our intellectual property
If you purchase the 52v controller, and decide later to go 72v, then you will need to return the controller only, to us to be remapped. this is free, but you will be asked to pay postage both ways.
We do not charge a fee for general support work (something is not working)
Controller Feature Set
- FOC (Field Oriented Control)
- improved torque throughout the rev range
- Higher RPM compared to the stock controller on 52V and especially on 72V (Up to 7500RPM)
- Silky smooth throttle control and responsiveness, like a fine adjustable knob on a light switch.
- Improved efficiency due to FOC algorithm, premium internal components within the controller (like the mosfets) which increases efficiency while reducing heat losses
- Automatic sensored to sensorless transition which gives you addition 5% top speed and better performance
- Can use Bafang display (Assist Modes are incompatible at the moment, other readouts would work, but you will only have one assist level which max power / speed)
- Supported displays are TFT 72V 750C (has a custom firmware that allows full compatibility with the BAC800 including assist modes, PAS, light, etc) and the Eggrider Display
- Includes 3D Printed Cover
- Usable voltage is 36V-92V
- Programmed for 3000W, # of Assist levels (Power / Speed Map) are set within the display and will scale accordingly. Example Assist 1-3, Assist 1 = 33% Power / Speed. Assist 2 = 66% Power / Speed. Assist 3 = 100% Power and Speed.
The kit includes:
ASI BAC 800 36V – 90V FOC 90A
Wiring loom to connect direct to existing BBSHD loom with Anderson Power connectors
Motor side cover
Free UK shipping
When ordering please supply your wheel size – thank you
- Lightweight and compact design keeping your handlebar clean
- Small enough to avoid unwanted attention
- Dust and water resistant – IP65 protection
- Voltage reading between 20V up to 60V
- First to detect real battery capacity and tracking stats of up to 3 batteries
- Android and iOS mobile apps for more statistics and configurations
- Providing flexibility to comply with road e-bike laws worldwide
- Ability to use the EggRider app as a larger display
- In-depth charts capability for your rides
- One button switch between two profiles
- Throttle yes/no
- Pedal assist yes/no
- Power level
- Size: 75mm x 47mm x 35mm
- Weight: 31g
- Cable length: 30cm
- Handlebar mounting bracket: standard 22.2mm diameter
- Physical buttons: Power On/Off, Level Up/Down and popular Road/OffRoad mode switch
- Connector: Higo/Julet waterproof 5 pin male/female (see image)
- Bluetooth low energy (BLE)
- Compatible with e-bikes based on Bafang motors (including Sondors), Lishui and Kunteng controllers and many other brands we keep discovering
- Hex bolt: M3
- Mounting clamp pin: 2.0mm diameter and around 15mm length
Help and instructions:
Gearing (video tutorial to follow or call for explanation):
Use a 42T front Chain wheel to “Clam Shell the motor and bring the chain line inbound – we sell a cheap Lekkie clone version)
Reduce your rear cassette size to improve the chain line, removing any gears smaller than 15T and create your perfect centre-line around the 26T/28T rear sprocket (depending on wheel size)
Remove the old 9 -10=11 speed cassette and use the gear range from 15T to lowest gear. We love the Shimano XT CS-M771-10 speed cassette as shown in the photo. Use spacers to give you a perfect chain line for the gear of your choice. For 27.5 and 29er set ups we recommend a 28T rear gear. For 26″ wheels a 26″ T gear. For fat bikes as big as you can get! (32T +)
If you want to be very smart, you can use a 2.35 mm spacer from your old cassette to space out a 17T as a “Get you home” cog for pedaling or PAS assist in power level 1. But you might have to manually put the chain onto the cog. Use your old derailleur as a tensioner and give your self enough chain (we recommend KMC x10e chains) to move up and down you have. You will want to adjust your max/min screws so the chain does not slip off the outer sprockets (You may need to change these for longer screws)
Photos of rear gears and spacers are not included
Graham C I don’t think the BBSHD is weak as people say. Abuse it yes and something will fail just like any mechanical product. My motor was purchased from Francis Janssen in November 2017. Since then I have completed 7000 miles with approx half of those miles with a Luna Ludicrous controller fitted. My 20 miles daily commute, downhilling, bmx tracks, trails the lot ! I’ve not touched anything internally on the BBSHD and it’s running better than ever, all these stories of nylon gears failing I’m sure is down to the rider, have some mechanical sympathy and you’ll be fine. As Francis states I have now fitted the ASI 800 running on 72v, I followed his advice, got my chain line in order, correct gearing and 500 miles later she is absolutely flying, a weapon indeed. It’s far exceeded my expectations, high revving, smooth ramp up of power, throttle response, acceleration is crazy compared to the Ludicrous, top speed, all fantastic and so much fun, it does not feel like the motor is working hard. I am extremely pleased. I can thoroughly recommend this conversion and Electron Cycles ( Francis Janssen) for there professional services. Go for it !
72V 15 Ah Triangle Water Tight “Tough”Battery 60A Samsung 30Q + 5A Charger
72v 15Ah (20s5p) Samsung 30q on/off switched XT90 connector Ebike, Electric Bike, Triangle Battery with 5A UK Charger
This is the very best of battery technology: 20s5p Ah battery containing 1oo Samsung 30Q 3000mAh 18650 cells, 60A BMS (battery management system) with 5A UK charger. 60 Amp Nominal BMS. Designed to fit within the triangle using a choice of 9 Velcro fastening points.
These type of cells used in high amp discharge installation where the combination of 15A per cell maximum discharges yet a storage capacity of 3000 mAh. They are specially designed for high output discharge. Other inferior cells used in cheaper packs simply cant deliver like these in this scenario. These batteries are particularly good for: large rear hub systems of 3000watts, Cyclone mid drive and BBSHD Phase runner conversions, MXUS hubs. Cyclone cyc X1 Pro and ASI BAC 800 BBSHD These cells can supply a nominal 3000 watts (depending on charge state) a nominal.
This is a post from Facebook from one of our test riders (BBSHD with ASI BAC 800):
60A (restricted by the BMS) and bursts much higher.
If you think the cost is high, these batteries have 100 cells that retail in the UK for around £6.50 each! not including a BMS, casing , charger, shipping taxes AND FABRICATION.
These are factory made using the very latest in spot welding and nickel strip.
Please ALSO note, these are genuine cells and made up into complete battery specially to order for me at the factory. We can’t simply buy a single battery; I have to agree to a production run of at least 20 batteries.
The cases are extremely tough and weather resistant to a high degree. They are designed to take a medium impact.
Not all triangles are the same, please use the link below to download and print two A4 pieces of paper that create a life size template.
The battery is 365 mm in length and 235 mm in height. The width is just 80 mm.
Template download (print on A4 Paper and align):
* 12 Month Warranty is for manufacturing defaults and does not over miss use or accidental damage. Opening battery will void any warranty.
Please note, Lithium batteries are considered hazardous and due care and attention should be taken. Although these cells are in wide use, and professionally manufactured in a purpose built factory; because of the power of the battery, we strongly recommend that precautions are taken. We do not recommend charging inside the family home and charging should be supervised. We take no responsibility for misuse. These batteries are thoroughly tested (full discharge and charge cycles at the manufacturing stage and also pre-delivery). These are not DIY or amateur built devices.
Please connect and remove the charger, and charge with both the battery and charger turned on.