E-max 110s lifepo4 upgrade

[yokneamcity]

Hi all!
I've found the right combination to connect the Lyen Infineon controller to the E-max motor.
Hall sensors
Controller/ Motor
Blue-Blue
Yello-Yello
Green-Green

Phases
Controller/ Motor
Blue-Yello
Yello-Blue
Green-Green

One of the combinations was as Flexy conected.
The motor is spinning very fast and current 30 amps with no load.

[yokneamcity]

I looked again a video of Flexy. And drew attention to the no-load current. 30A!
76.6V * 30A = 2500Watt no-load
When properly connected current should be about 5A.

[flexy]

Glad you got the hall combination worked out how is your scooter performing with the new controller? are you using it at 48V or 72V?

I looked again a video of Flexy. And drew attention to the no-load current. 30A!
76.6V * 30A = 2500Watt no-load
When properly connected current should be about 5A.

That current reading is incorrect, I hadn't set the shunt value in the CA, it was set at 1 mOhm but that controller is actually 0.26 mOHM. The controller was still warm so I think you were correct about the hall combination, I will test again when I have my Lyen controller repaired.

[Tommy L]

Nice work here!
Powerful 5kw hub in a small wheel. Does it take off quick?

Tommy L sends.... \\m//

[yokneamcity]

Today I did a test drive with the new controller 18FET Infineon.
Cycle Analyst showed a maximum power of about 2 KW. (This is the default setting of the controller)
I wanted to go home and change the controller settings to 5 KW and try again. But as I placed the controller under the seat, and he did not have enough air flow, strongly heated. Phase connectors were also hot. I think the standard connectors are not suitable for high currents and need to be replaced by more powerful. These are the example http://www.hobbyking.com/hobbyking/stor ... pack_.html.
I decided to change my 18FET controller to a more powerful 24FET and to continue the test drive
And to set the controller in such a position that he had sufficient airflow.

[yokneamcity]

I found a way how to activate the MCU unit without 48V
Pin 8, 12 volt feedback, controls the relay. The relay sends 48 volt to 48/12 Volt regulator.
It is possible to connect 12 volts from external DC/DC (78V to 12V) to the output of the Voltage regulator on MCU board.

[flexy]

Yes, that's the way I got it to work

These are good for phase connectors http://www.torberry.co.uk/superbasket/product/238/75A+Powerpole+Pack+-+any+colour+-+2+hsgs+%2B+2+x+10mm+contacts

[flexy]

It is possible to connect 12 volts from external DC/DC (78V to 12V) to the output of the Voltage regulator on MCU board.

Can you show where that connects on the MCU?

[yokneamcity]

It is possible to connect 12 volts from external DC/DC (78V to 12V) to the output of the Voltage regulator on MCU board.

Can you show where that connects on the MCU?

Sorry for the late reply. I connected it in this way.
+12V to CN1_pin8,CN3_pin1,CN5_pin1.
-12V to CN1_pin13/14.
I unsoldered Q3. This mosfet worked in PWM mode and supplying 12 volts to the light (from 48 volts).
I shorted R58/R59 resistors for the signal horn.(Now it work with 12V instead 48V)
I also unsolder the relay and short it. But do not necessarily.

[flexy]

that's some good work.. was your MSU covered in the black epoxy?

[yokneamcity]

:D that's some good work.. was your MSU covered in the black epoxy?

No.My MSU was not covered in black epoxy,lacquer colorless only.

[flexy]

Mine has the black epoxy so I can't do those modifications you show.

I have ordered a greentime 36fet controller with IRFB4110 fets , hopefully that will handle the power requirements of the motor.

[yokneamcity]

I installed the 24FET Infineon on my scooter. The controller did not get enough air flow and strongly heated. I added it to the two fans, and it solved the problem. Instead of the original controller, DC / DC converter for 12 volt.
Top speed increased from 42 km/h to 50 km/h (52V battery)
Significantly increased dynamics. Maximum current of 100 amperes at the start.
The original speedometer is connected to the green wire in the Cycle analyst connector .

[flexy]

That's a tidy installation, nice!

I'm surprised you are getting that controller hot, I expected it to handle the power better.

Maybe when you raise the voltage it will run cooler, more volts=less amps?

[yokneamcity]

That's a tidy installation, nice!

I'm surprised you are getting that controller hot, I expected it to handle the power better.

Maybe when you raise the voltage it will run cooler, more volts=less amps?

Thank You!
It handle the power. Efficiency of the controller is not 100 percent. Part of the power converted into heat. We must help the controller to dissipate the heat on his body.

[flexy]

That controller is supposed to handle 10KW, you are using 6KW max, what air temperature are you using it in?

[yokneamcity]

That controller is supposed to handle 10KW, you are using 6KW max, what air temperature are you using it in?

+30-35 C

[flexy]

+30-35 C

Nice!

I got my 36 fet today, it's quite big compared to Lyen 18fet

[yokneamcity]

+30-35 C

Nice!

I got my 36 fet today, it's quite big compared to Lyen 18fet

This monster controller!
Where you will plase it?

[flexy]

This monster controller!
Where you will plase it?

I have yet to work this out

[flexy]

This is my battery pack design ,based around the A123 20Ah cells, it consists of four modules each containing 30 cells.

The tabs on each will be bolted to the copper plate to make 5p groups.

The chequer plate cases are the only thing I could get made at short notice. They do present a risk of shorting so I will have to insulate them on the inside at least. I would prefer to use G10 epoxy sheet as it is a good insulator and very rigid + heat resistant.

Each 30cell module will have steel straps to compress the cells and stop any movement.



Download the Sketchup file here https://dl.dropbox.com/u/8208701/Electric%20scooters/Emax%20battery.skp

[yokneamcity]

I finished work on remaking the battery. Battery had three assemblies of 16 cells in series. That were are connected in parallel.(16S/3P) Prismatic packages A123 20 A/H
I decided to pick up the battery voltage to 78 volts. For this, I middle the assembly parted into two parts, each with 8 cells. And added to the two assemblies are 8 cells. The result was a configuration 24S/2P.
Maximum speed increased to 72 km/h.
And also i ordered BMS 24S/100A rated current from BMS_Battery http://www.bmsbattery.com/bmspcm/378-17 ... t-bms.html
In this BMS installed low quality mosfets with high-resistance channel. This has caused a strong heating BMS at maximum current (100A)
But I solved the problem.I connected the controller power cable to the battery directly, through a fuse, bypassing BMS. Logic Plus of controller is connected through a relay that is connected to the battery through the BMS.

[flexy]

72 km/h! I was hoping to get more at that voltage, it's still a good improvement. What sort of range are you getting?

That's a good idea to use BMS to switch a relay. I was thinking of doing the same with my Evassemble BMS, then I can send regen current straight to the battery too.

I'm still waiting for a new controller so no progress yet

[yokneamcity]

72 km/h! I was hoping to get more at that voltage, it's still a good improvement. What sort of range are you getting?

That's a good idea to use BMS to switch a relay. I was thinking of doing the same with my Evassemble BMS, then I can send regen current straight to the battery too.

I'm still waiting for a new controller so no progress yet

72 km/h according to gps, and proximity 80 km/h according to car speedometer.
I gated 50 km range with 72 km/h speed and 100 km range with 50 km/h speed.