12 FET 84-132V High Voltage Racing Controller - LYEN $199

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12 FET 84-132V High Voltage Racing Controller - LYEN $199

Postby Lyen » Thu May 06, 2010 6:12 am

Introducing the newly brewed 12 FET 84-132V Infineon Programmable Brushless Controllers with high voltage IRFB4115 MOSFETs (EC124115-LYEN EDITION)

This is for a new, never used high voltage controller for racing in mind. It is originally designed people who have the gut for going above 40mph or 64kph. You are entering the light-motorcycle territory with this controller. :)

There are other reasons for utilize the controller below:
1. You want to give higher speed to your beefy and robust high torque low speed motors such as the Crystalyte 5306, 5305, 5304, 4011, 409, 408, BMC V2 Torque version, E-BikeKit 6x10 slower winding motor, Nine Continent - 9C 2807, Golden Motor HBS36 series, etc.
2. You have hub motors 20” or smaller high torque wheels and need to find a way to boost significant speed
3. You have a hall sensors added RC motor (Turnigy & Astro in this case) but want to take the advantage of higher RPM or to improve the gear ratios for more torque and/or speed
4. You hate getting horned by cars behind you telling you to get out of their way
5. You think high voltage is cool
6. You want to horn cars in front of you telling them they are too slow
7. You want a high voltage high speed controller in a small enclosure/chassis
8. You want to win the Spooky Tooth Death Race and compete against gas engine cycles after all
9. You want to combine your two 48v battery packs in series together for the high speed experience at 96v
10. You want to combine your three 36v battery packs in series together for the even higher speed experience at 108v

One unique design is the welcome of the embedded switching power circuitry to step down the high voltage and feed the MCU (motor control unit). The static-state current switch module that draws only 22mA, which is about 1/3 current draw of the current controllers using the high power resistor. This way, the controller will run much cooler and more energy efficient.

Another unique feature of this controller is that it has an additional speed sensor circuitry built-in with an extra output lead/pin. It is to be used with the scooter style electric bike and electric scooters that have a speedometer in the dashboard that reads electrical pulses.

This version also uses lock washers to secure the MOSFET transistors internally and the heat transfer bar outside to place tension against a nut after tightening. It is also to help prevent the nut from loosening. The MOSFET transistors will get overheated and damaged when detached from the heat-sink which used to be the case from the previous designs.

By purchasing the controller, you understand the following:

1. Your electric bike may classified as a motorcycle class vehicle in most states
2. Riding at high speed may not be legal on public road without proper driver’s license and auto insurance.
3. Risk of high voltage shock with improper high voltage batteries handling
4. Safety wears is advised and may required by law in most states
5. Typical bicycle cantilever, rim, and even disc brakes may not have sufficient stopping power
6. Typical bicycle frames are not designed for high speed application
7. Motorcycle class/training course(s) is highly recommended to ride safely at high speed

Note: Do not use a regular Cycle Analyst due to high voltage will destroy the internal circuitry. You should use the controller with the CA-LS model only.

This is a top of the line controller that comes with all the bells and whistles that are typical needed for the racing application including the CA connector, regen enable/disable jumper, USB-TTL plug, USB-TTL programming adapter with a push to send button and connector. Windows XP/Vista/7 32/64 bit operating system (real 32/64bit drivers). A special LVC calculation formula will be provided via PM or email upon purchase.

The size for the 12 FET controller is as follow. The end to end is 180mm with the mounting plate. Case end to end is 154mm with screws sticking out on each side. The height & width is same as the 18 FET one at 87 x 45mm.

Below is the specification:
Model: EC-124115-LYEN EDITION
Start immediate controller
Chipset: XCKJ8B116A (same chipset being used as in the 18 FET controller)
Circuit board version: Confidential
12 x genuine IRFB 4115 MOSFET N-CH 150V (tested up to 150V before damage) for more information about the FET, click the link below:
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=IRFB4115PBF-ND)
120V battery optimized (for higher or lower voltage & current such as 84V-132V, you may need to program the low voltage cutoff. Be aware the absolute battery topped off or fully charged voltage cannot exceed 150v)
30A is the current rate (for higher current, you may need to beef up the trace, shunt, and reprogram it via the software)
Low voltage cut-off at default: 95v (User adjustable)
Battery and motor phase wires gauge size: 12AWG (High voltage capable wires equipped)
Dimension: 6.2" x 3.4" x 1.75" (155mm x 87mm x 45mm) plus mount extensions
Total weight: 515 gram

I have only 20 made since I am busy working on my other ebike projects. My intention for selling at such low price is to share the fun with other ES forum members instead of making them jealous. :wink: I finally understand why Methods mentioned the cost of labor is steep after all this and I have to agree with him from now on. These controllers are not generic controllers. I have every single one serialized. Quantity is limited, buy it as soon as your piggy bank is filled up. :lol:

$199 USD free ground shipping in the United States & Canada. For other locations, please PM or email me at LYEN@HOTMAIL.COM. I accept PayPal, cash or money order. The controllers will be shipped out from me in San Francisco, California, USA. I will provide a tracking number and ship it out as soon as I have received the fund.

You may click on the PayPal Buy It Now link below. For accessories, please send money via PayPal or send me a private message for the total price. Thanks!

https://www.paypal.com/cgi-bin/webscr?cmd=_s-xclick&hosted_button_id=UAGZSS64MCFTQ

If you are not satisfy with the results or if it is too fast for you, you may send it back to me within 30 days in an unmodified condition.



Quantity updated as of 5/16/2013 : 19 left (buyer bought 1 from kula, HI)
Quantity updated as of 5/27/2013 : 18 left (buyer bought 1 from Kula, HI)
Quantity updated as of 5/29/2013 : 17 left (buyer bought 1 from Montreal, Quebec, Canada )
Quantity updated as of 6/19/2013 : 16 left (buyer bought 1 from Brisbane, Queensland, Australia )
Quantity updated as of 6/24/2013 : 15 left (buyer bought 1 from Coimbra, Portugal )
Quantity updated as of 6/27/2013 : 14 left (buyer bought 1 from Linz, Austria )
Quantity updated as of 6/28/2013 : 13 left (buyer bought 1 from Vancouver, WA )
Quantity updated as of 8/1/2013 : 12 left (buyer bought 1 from Silkeborg, Denmark )
Quantity updated as of 8/5/2013 : 11 left (buyer bought 1 from Chezy sur marne, France )
Quantity updated as of 8/11/2013 : 10 left (buyer bought 1 from Oslo, Norway )
Quantity updated as of 9/9/2013 : 9 left (buyer bought 1 from Skui, Norway )
Quantity updated as of 9/16/2013 : 8 left (buyer bought 1 from Brossard, Quebec, Canada )
Quantity updated as of 10/14/2013 : 7 left (buyer bought 1 from Pitt Meadows, BC, Canada )
Quantity updated as of 11/14/2013 : 6 left (buyer bought 1 from Dracut, MA, United States)
Quantity updated as of 11/15/2013 : 4 left (buyer bought 2 from Ashland, OR, United States )
Quantity updated as of 5/5/2014 : 3 left (buyer bought 1 from Brisbane, Queensland, Australia )


Image
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Additional accessories (prices are reflected with controller purchase only. Please contact if you are interested to buy without controller):
$15 throttle (full/half/thumb) with mated left rubber grip (very good quality) (ebikekit retails @ $36)
$19 cruise control (manually installation required)
$15 three way speed switch (manually installation required)
$15 PAS - Pedal Assist System add-on (manually installation required)
$15 electric brake levers a pair
$29 motor/controller hall/phase/throttle tester
Last edited by Lyen on Sun Jun 22, 2014 10:14 am, edited 51 times in total. View post history.
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby grindz145 » Thu May 06, 2010 5:44 pm

Lyen these look like an AMAZING off the shelf option. Building these up is a ton of work (and well worth it).

What current have you tested through this?

Nice work man.
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Re: 12 FET 84-132V High Voltage Racing Controller LYEN $199

Postby Lyen » Thu May 06, 2010 5:57 pm

grindz145 wrote:Lyen these look like an AMAZING off the shelf option. Building these up is a ton of work (and well worth it).

What current have you tested through this?

Nice work man.


Hi Grindz145!

Thanks for your compliment on the controller! :) The traces on the MOSFET output portion have been re-enforced for 60-65A peak. However, there is no off the shelf high voltage battery pack as of today. The only people who know how to DIY their 25S Lipo and above or link their batteries together will be interested I believe. :)

Best Regards,
Edward Lyen
Last edited by Lyen on Fri May 07, 2010 11:53 pm, edited 1 time in total.
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby johnrobholmes » Mon May 10, 2010 9:34 pm

How fast could this controller spin a sensored astro motor? 24 slot, 8 magnet.
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Lyen » Tue May 11, 2010 8:53 am

Hi John!

Thanks for your interest in the high voltage controller! The maximum speed tested is around 6600 RPM as of today, which is plenty fast to push the bearings limitation to the ceiling on most hub motors. The RPM speed will be the same for the sensored Astro motor as well. :)

johnrobholmes wrote:How fast could this controller spin a sensored astro motor? 24 slot, 8 magnet.
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Re: 12 FET 84-132V High Voltage Racing Controller

Postby Lyen » Sat May 15, 2010 5:22 pm

I have purchased and received more MOSFETs. Sale resumed as of 5/21/2010 @ 6:22pm PST. :)

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By elyen01 at 2010-05-21
Last edited by Lyen on Fri May 21, 2010 8:25 pm, edited 1 time in total.
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Re: *SOLD OUT**12 FET 84-132V High Voltage Racing Controller

Postby methods » Mon May 17, 2010 4:52 pm

Did you try IRTronix?

Too bad... I have hundreds of IRFS4115 fets. I should have gone with IRFB4115's and then I could have sold them to you!

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Re: *SOLD OUT**12 FET 84-132V High Voltage Racing Controller

Postby Lyen » Tue May 25, 2010 3:41 am

methods wrote:Did you try IRTronix?

Too bad... I have hundreds of IRFS4115 fets. I should have gone with IRFB4115's and then I could have sold them to you!

-methods


Hi Methods!

Thanks for telling me to try from IRTronix. I was able to get more for more controllers. :wink:
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby methods » Tue May 25, 2010 10:38 pm

I forgot to tell you to ask for Mike at IRTronix.
Mike is a friend of the Electric Revolution.

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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby tostino » Wed May 26, 2010 4:00 pm

Lyen, what are the chances of parting with 24 of em? Or do you think the Mike guy would be willing to sell me them in such a low quantity? I'd love to get the two controllers for my dual motor bike built up.
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby methods » Thu May 27, 2010 12:48 am

Sorry to hijack -

Mike at IRTronix will sell in quantities of 100 I believe but the prices wont be that hot.
You really need to buy thousands to get the kind of killer deals I was sharing.

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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Knuckles » Thu May 27, 2010 9:53 am

Lyen,

Be sure to mod the R12 circuit. As designed now the R10 and R11 will overheat.
Do the math ...

-K

Image

See my post here ... viewtopic.php?f=4&t=18065&start=15#p265427
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Knuckles » Thu May 27, 2010 10:06 am

Also,

The VR circuit components are susceptible to burn out from initial current surge.
These components only have a max rating of 100V to 120V. The resistors are maybe 1/8 watt.

I use a FJP9100 transistor circuit to keep the voltage to the VR circuit under 100V.
Side benefit of this mod is it makes the unit "any voltage" 39V to 150V.

I also add a temp switch to the fet heat sink.
Very simple to solve all these issues with a mod "module".

PM me and I'll share all my mods with you.
This way your controllers will be "bullet proof"

-Knuckles.

PS Nice fets!
PSS So methods has cornered the irfb4115 market too! :shock:
PSSS Have you tried tweaking the block times yet? Really cool post about that ...
viewtopic.php?f=2&t=18675&start=0#p272438
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby tostino » Thu May 27, 2010 10:28 am

Well damn. I guess my only real hope is a group buy, or if lyen will sell me a few =(
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Lyen » Thu May 27, 2010 11:41 am

tostino wrote:Lyen, what are the chances of parting with 24 of em? Or do you think the Mike guy would be willing to sell me them in such a low quantity? I'd love to get the two controllers for my dual motor bike built up.


Hi Tostino!

I apologize for not being helpful. I have pretty much soldered all the MOSFETs onto the circuit boards prior I saw your post here. Let me see what I can do with the next badge of orders and get back to you.

Regards,
Lyen
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Lyen » Thu May 27, 2010 11:53 am

Hi Knuckles!

I valued your informative suggestions. You are truly the godfather of all Infineon controllers. I really appreciate it. :)

Best Regards,
Edward Lyen

Knuckles wrote:Also,

The VR circuit components are susceptible to burn out from initial current surge.
These components only have a max rating of 100V to 120V. The resistors are maybe 1/8 watt.

I use a FJP9100 transistor circuit to keep the voltage to the VR circuit under 100V.
Side benefit of this mod is it makes the unit "any voltage" 39V to 150V.

I also add a temp switch to the fet heat sink.
Very simple to solve all these issues with a mod "module".

PM me and I'll share all my mods with you.
This way your controllers will be "bullet proof"

-Knuckles.

PS Nice fets!
PSS So methods has cornered the irfb4115 market too! :shock:
PSSS Have you tried tweaking the block times yet? Really cool post about that ...
viewtopic.php?f=2&t=18675&start=0#p272438
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby tostino » Thu May 27, 2010 12:07 pm

Lyen wrote:
tostino wrote:Lyen, what are the chances of parting with 24 of em? Or do you think the Mike guy would be willing to sell me them in such a low quantity? I'd love to get the two controllers for my dual motor bike built up.


Hi Tostino!

I apologize for not being helpful. I have pretty much soldered all the MOSFETs onto the circuit boards prior I saw your post here. Let me see what I can do with the next badge of orders and get back to you.

Regards,
Lyen

You have no idea how much I would appreciate that! Thank you very much.
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Knuckles » Thu May 27, 2010 5:16 pm

Here you go ...

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High res pic here

peace 8)
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Arlo1 » Sat May 29, 2010 5:04 pm

subscribed
Thanks Justin at http://www.ebikes.ca/
Thanks to Methy at http://www.methtek.com/
And Dave who has Nomex, fets and current sensors etc. STUFF
My YSR build. viewtopic.php?f=10&t=18183
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Confirmed > no overheating issue on SMD resistors

Postby Lyen » Fri Jun 04, 2010 4:16 am

Dear all respective members and buyers,

Good news!

This is the clarification and response to the potential overheating issue on the SMD thin film resistors on R10, R11, and R12. I have escalated it all the way to the supplier as well as actual designers for the print circuit board. We both have executed a series of testing including highest voltage, highest temperature, highest motor rotation, as well as highest current drawn. The resistors on R10, R11, R12 pads actually do not take direct voltage from the battery. Therefore, the current and power draw is more than sufficient with the SMD resistors.

Here is the hard evidence with the tested results executed in San Francisco, California, USA:

The voltmeter and the EC-124115-LYEN Edition controller being used for testing at 155.9V (Do not try this at home! It is very dangerous!) :shock:
Image

Temperature meter with the probe sensor being used (The probe is quite sensitive) :)
Image

R10 resistor temperature result shown in Celsius after one full hour:
Image

R11 resistor temperature result shown in Celsius at the second full hour:
Image

R12 resistor temperature result shown in Celsius at the third full hour:
Image

As you can see, the overheating issue was incorrectly informed previously. We can conclude the case is now dismissed. :D

Your Truly,
Edward Lyen


To see my test equipment, click here:
http://img227.imageshack.us/img227/2429/testequipment.jpg
Last edited by Lyen on Fri Jun 04, 2010 8:19 pm, edited 1 time in total.
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Knuckles » Fri Jun 04, 2010 6:53 pm

#1) Buy from Lyen. I like Lyen and I think he builds EXCELLENT controllers. A+ Lyen.

#2) This statement is incorrect ...
Lyen wrote:The resistors on R10, R11, R12 pads actually do not take direct voltage from the battery.
This is false. R10, R11, R12 resistors absolutely DO take direct voltage from the battery.

#3) I just measured the current thru the R10-R11-R12 circuit on an isolated "naked" XieChang pcb.
At 152 volts the current thru this circuit is 8.6 ma just as I had predicted.

#4) Fortunately the 12-fet controller tested by Lyen has a large capacitor directly above R10 and R11.
Clearly this large cap is acting like a heat sink and helps "save" these components from overheating.

Please realize that the 6-fet, 18-fet, 24-fet and 36-fet MAY NOT have a large cap directly above the R10 and R11 'lil' resistors.
Just a FYI to all the folks whom like math.

Buy Lyen ... Stay lean!

cheers,
-Knuckles

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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Lyen » Sat Jun 05, 2010 4:32 am

Hi Knuckle!

I thanks again for your commentary and compliment. The direct battery connection was actually interpreted incorrectly as the original word by word translation meant connect both positive & negative to each individual component such as the resistor from end to end. :)

Anyway, I am seriously listening and made the change to make sure the controller is 100% reliable and last for years although it is not really necessary. The higher wattage resistors are now used. Below is the improvement:

Image

Best Regards,
Edward Lyen
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Tom_D » Thu Jun 10, 2010 12:28 pm

to Edward,
Pm sent

-- Tom
Bike: wally world 26" Roadmaster mtn
Trailer: Bob
Motor: front Clyte 5305
Controller: LYEN 124115 HV
Charger: Soneil 4808 SRF (onboard), parallel charging (4) 48V blocks, NO BMS
Batt: 84s2p Toyota Prius Gen III
Dashboard: Cycle Analyst
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Re: 12 FET 84-132V High Voltage Racing Controller - LYEN $19

Postby Lyen » Thu Jun 10, 2010 12:52 pm

Tom_D wrote:to Edward,
Pm sent

-- Tom


Hi Tom!

PM replied. I appreciate your business and your hint to deliver to Hawaii. :)

Regards,
Edward Lyen
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