Delta wound golden pie with 24 fet controller

[zappy]

Hi, I have a golden motors magic pie which has been changed from wye to delta.The internal resistance has dropped from 216 milliohm to 65mmilliohm. New hall positions have been set up with a scope. The hub has 4 internal fans with heavily drilled side plates and 8 guage phase wires. the motor runs sweet It pulls about 240watts free rpm on the cycle analyst doing 80km/hr with a 470mm diameter motorcross tyre on a 14"rim(wheel off the ground). But with the EB224-asi 24 fet controller the motor surges/hunts and cuts back the current to approx 3500W. For a couple of months i have had to stick with my 12 fet it runs great but with only 3100w (the controller gets very hot of course) but when i swap it back to the 24 fet it current limits and surges. When it does run up to 5000w it feels great, with heaps of torque and is a great ride. I have tried another 24 fet controller(thanks toolman2) but with the same surging problem. Battery pack is 20 A123 cellls = 66V 20AH. What is happening? How can i fix this? Software? Inductors on the Phase wires? Please use small words i am more mechanical than electrical.

Thanks Guy

[neptronix]

I wish i could help you, but......

Dude, can you post some pics of your fan setup?

[zombiess]

What have you programmed your 24 FET to? My 36 FET is sucking down over 15KW during acceleration (130A limit with 125V battery pack sagging about 7 volts) and it doesn't even get slightly warm. A 24 FET with IRFB4110 FETs should be capable of quite a bit of power as others on here have done. Guys like Farfle are running their 24 FET controllers (modded) into the 20KW range for bursts.

Do you have a cycle analyst or any other external devices that might limit your current? I know I'll get surge if I'm in the high shunt range setting and exceed the 99A setting on the cycle analyst because it tries to limit it.

Also as neptronix asked, post some pics of your setup, this sounds like a neat setup and I want to see what you did.

[John in CR]

Disconnect the CA and give it a try.

Otherwise, does it repeat while riding or just on the first pull, or every acceleration? If every acceleration, then maybe it's Block Time simply allowing the high current for that set amount of time and you have the current limits set too low for your need. If more intermittent maybe you have a bottleneck in the wiring or a connector that heats up.

[auraslip]

If you post pictures, I'll help you.

JK. Unplug the CA. May have amp limiting. Do you have the software programer? Change the current and phase limits.

[zappy]

Thanks neptronix zombiess ,john in CR and auraslip for your input. Sorry i have not got back with update. I considered everything said. But it was toolman2 that fixed it. The tiny R12 resistor is low voltage cut out. So we removed that and it now has 8Kw in and offers heaps of grunt. Infact in the short 2Km test ride at 1 a.m In the morning i was doing a wheelie at about 40km/hr accelerating upto 50km/hr just past the balancing point i remembered i had removed the back caliper! I'm on crutches now.

Wife rant: It was dark! you drank how many? 10 beers! How much more power do you have than you should? 40 times! How did you fall off? wheelstanding again! What were you thinking?

Zappy: How much fun it was.

[auraslip]

Wife rant: It was dark! you drank how many? 10 beers! How much more power do you have than you should? 40 times! How did you fall off? wheelstanding again! What were you thinking?

Zappy: How much fun it was.

I love this post so much.

[zombiess]

LOL

Did you break anything or are you going to be OK? It's never acceptable to drink and ride... ever.

Is it fast now, just remember, you don't need to pedal so you can still ride even if you are on crutches.

[methods]

The tiny R12 resistor is low voltage cut out. So we removed that and it now has 8Kw in and offers heaps of grunt. Infact in the short 2Km test ride at 1 a.m...

I know this is an old thread but it came up on a Google search for EB224 and there is a piece of misinformation that I want corrected.

Just to clarify when he says "removed that" what he means is that he replaced that resistor with one that was slightly larger so that the uController saw a voltage was above the point at which LVC should be applied. "removing" R12 would result in applying full system voltage to the A/D input of the uController through resistors R10 and R11... I guess the zener clamps on the chip might save you but that is a very bad idea. R10 and R11 are tied directly to system voltage, R12 is the lower leg of that divider, uController A/D input touches the top of R12

I wanted to clarify so that some poor sap down the road did not think that it was ok to remove R12.
Removing R12 would be a very bad idea and would only be survivable by pure luck.

-methods