ALL NEW 150V-30A XieChang CONTROLLER

[dnmun]

maybe he meant for the 'fyb' space to be the spot for a fuse.

if you up the current, are you gonna build up the traces next?

you outdid the original now.

[Knuckles]

I don't plan on beefing up the original traces,
just the small trace that goes to the Cap C202 ...
*

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50 Amps is pushing it a bit for the 13 AWG wires anyway. Same for the 12 irfb4115 mosfets.
I expect that the existing traces and the 13 AWG wires will get hot at 50A continuous.
Heck that would be 150V x 50A = 7500 WATTS (10 HP).
That is pretty insane for a 12-Fet controller
I am sure that would melt a 9C motor!

Two things bother me however ...
1) The thermal switch might fail at 150V when opening and closing.
2) The small (~18k total) surface mount R12 circuit resistors (R10 & R11) may fail at 150V.

The pic below is the R12 circuit on the 24-Fet pcb (same circuit used on all XieChang pcbs).
*

R10_11_12.jpg (89.16 KiB) Viewed 906 times

I might need to address these two issues also for true 150V operation.

[Knuckles]

On controllers, I do my R&D mostly for the enjoyment of it.
My goal is an "any voltage" controller 48 volts to 150 volts.
The "size" of the controller determines the current ...

(continuous current) from smallest to largest ...
6-fets = 25 amps
12-fet = 50 amps
18-fet = 75 amps
24-fet = 100 amps
36-fet = 150 amps

all units would be "any voltage" 48 volts to 150 volts.

BUT ... XieChang (manufacturer) designs only for 72V max ...
Thus my mods are essential to exceed the original design criteria.

NEWS FLASH ... ALL NEW High Voltage 6-fet Controller comming soon!
So it looks like the 6-fet THRU 36-fet controllers will ALL have the on-board VR circuit!

NICE!

[Knuckles]

[etard]

Nice, I will be looking for one of these 6 FET's you speak of. Is Keywin the seller of these, or are you selling them??

Thanks fr all the detailing pics, nice to be able to look at the inside of something before purchase.

[dbaker]

Knuckles,

Is that a 9C in the video? How did it like 4.5 kW? What was speed at WOT?

Dave

[Knuckles]

Knuckles,
Is that a 9C in the video? How did it like 4.5 kW? What was speed at WOT?
Dave

That red hub is an original "Grubee" motor I bought from Roland at "SpookyTooth" years ago.
That motor sits outside ALL YEAR LONG!

Similar to a 9c and/or GM I suppose. It just loves the high voltage. No worries. No heat at all.
The red motor was rated 48V 500W maybe. Just a winding difference. That's all.
Black "version" on my chopper is a little faster. Can't wait to pump that up to 10 x 12v = 120V (nominal).
(144 V off the charger).

PS ... My NiMH bats suck (old old bats) so I was only doing 35 MPH due to voltage sag.
But that is plenty fast for that POS cheap bike from Target. I want the chopper doing 50 MPH.
For that I will need all new bats. LiPo Turnigy seems the latest craze these days.

[Knuckles]

Nice, I will be looking for one of these 6 FET's you speak of. Is Keywin the seller of these, or are you selling them??
Thanks fr all the detailing pics, nice to be able to look at the inside of something before purchase.

I will sell them because I am the only one who mods them correctly.
(Steveo is close however ... He is more into the BIG units ... we collaborate).

6-fets = 25 amps $75
12-fet = 50 amps $150
18-fet = 75 amps $225
24-fet = 100 amps $300
36-fet = 150 amps $450

ball park prices (less $$ if you are INSANE!)

all 150V units (irfb4115) come with ...
* Good Capacitors
* CA Connector
* Any Voltage FJP9100 transistor "mod"
* All New R12 circuit "mod"
* 100C Internal Temp shut off
* PP connectors
* Two e-brake wires

btw
* "lil" red 60V switchers are $15 each
* FJP9100 transistor mod parts are $5

Shipping is USPS FR BOX (whatever fits in the cheapest FR box)

* SORRY. NO RETURNS. ALL SALES ARE FINAL.

[deVries]

6-fets = 25 amps
12-fet = 50 amps

ball park prices (less $$ if you are INSANE!)

Can the shunts be modded on these two with more solder/wire to carry more amps AND not fry something on the controller?

What can these handle for so called burst amps before doing any shunt mod? How many seconds are "burst amps" anyway?

Thanks!

[Knuckles]

6-fets = 25 amps
12-fet = 50 amps
ball park prices (less $$ if you are INSANE!)

Can the shunts be modded on these two with more solder/wire to carry more amps AND not fry something on the controller?
What can these handle for so called burst amps before doing any shunt mod? How many seconds are "burst amps" anyway?
Thanks!

Mod away my friend. Also check Lyen's offering here ... viewtopic.php?f=31&t=18214
And review this post by mwkeefer ... viewtopic.php?f=2&t=18675&start=0#p272438

-K

[andreym]

Well I finally got it all together. I re-flashed the MCU and set the amps to 50A.

When the LEFT e-Brake alone is slightly pulled (BK to GND is shorted) the throttle will allow variable regen.
When the RIGHT e-Brake alone is slightly pulled (EBS to GND is shorted) the controller shuts off.
When BOTH e-Brakes are applied the controller applies max regen to a stop.
*
-Knuckles

Can you share how to make this mod? I`d like to add this mod to Lyen`s 18fet controller - is it possible?

Thanks in Advance,
Andrey.

[Knuckles]

viewtopic.php?f=31&t=18214&start=15#p272971

The ebrakes are simple. The mod (link above) is for 150 volt with irfb4115 mosfets.

[mwkeefer]

Knuckles,

6FET me will ya?

Seriously any stock? Looking for FETs too (4110s/4030s, whatever I can get)

TIA!

-Mike

PS:

I'll happily take unbolstered controllers and build them myself, not a problem here - becoming an artist with 8G solid and some handy mini HiTemp C clamps I made to keep the 8G on the traces... made templates too (should I upload them in PDF format for everyone to share?)

[Knuckles]

DANG!

Still testing! Help anybody?

I hate soldering. I LOVE theory.

Seriously ... I welcome fellow scientists.

I've been so busy with work (like real job work).

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[liveforphysics]

Knuckles- For a given motor do you know what the current through the FETs has in common for the following examples?

50v 75amps
100v 37.5amps
150v 25amps

It's all exactly the same current loading through the FETs.

The difference is simply that the 150v rated FETs will be making about 3-4x the heat.

Be careful rating controllers by battery current values, as you know two controllers both pulling 25amps at 150v, one driving a 5302 and one driving a 5306, the controller driving the 5302 would have 3x the FET loading.

Likewise, if the motor's being powered aren't needing the additional RPM potential (like in the event of direct drive hubmotors where aero drag meets power limits), then running at a higher voltage only makes for plenty of additional liability and more controller heating with no advantages.

[Knuckles]

Knuckles- For a given motor do you know what the current through the FETs has in common for the following examples?

50v 75amps
100v 37.5amps
150v 25amps

It's all exactly the same current loading through the FETs.
The difference is simply that the 150v rated FETs will be making about 3-4x the heat.
Be careful rating controllers by battery current values, as you know two controllers both pulling 25amps at 150v, one driving a 5302 and one driving a 5306, the controller driving the 5302 would have 3x the FET loading.

Likewise, if the motor's being powered aren't needing the additional RPM potential (like in the event of direct drive hubmotors where aero drag meets power limits), then running at a higher voltage only makes for plenty of additional liability and more controller heating with no advantages.

Ahh! That's why I have a therm switch on the high side fet heat sink. 100C shuts it all down.

Good? Bad? Ugly?

[liveforphysics]

Good? Bad? Ugly?

Knuckles, I made a thread that covers the topic as best as I could.

viewtopic.php?f=2&t=19590

[Knuckles]

Finally ...



High resolution original step-by-step pics here ...
http://98.131.176.65/endless-sphere/150V30A/?N=D

btw ... Contact Steveo if you want one ... He likes soldering. I HATE soldering.
I like design.

F-N-A

-Knuckles