Well, I've got some really bad news for you guys. We blew the motor. We previously tested at 400A and 120V without issue. While it got HOT(outside can never got over 200F) , it seemed to be just fine. We tore the motor down and there were no indications of problems after that run. I'll have to let the cat out of the bag here and say we were running it on our Formula Hybrid car.
Our overall configuration was this: We coupled the motor to a planetary gearbox and from there it went to the diff. The drivetrain team was having issues sealing the gearbox and it had leaked some oil into the motor. We cleaned it out the best we could by blowing air through it, but the gearbox just leaked into it again. So, we cleaned it out again. Third time, apparently it leaked REALLY badly. We were doing an acceleration run and POOF. Black smoke. We pulled the motor off and on the bottom side, right where the oil would puddle in the motor, was a short in the windings that turned into a huge, 1/8 inch gap of missing windings. I think that the oil degraded the coating on the windings enough to where it finally just shorted and blew.
We ended up putting the Perm 132 and controller from last year on the car overnight...gaining around 15lbs in the process. Accumulator, by some miracle, got the pack reconfigured for the new power specs I gave them in just about 6 hours. Funny when it took 4 months to get it put together before...Anyway, I did some emergency machining and we are now running as a Hybrid again. We're going to be a bit slower and a bit heavier, but at least we'll be able to compete.
I apologize for not being able to get more data to everyone about the motor's performance. Let me tell you though...It really is a fantastic motor. Without the Drivetrain issues and with more testing, it would have been great. It ran REALLY well when it was running. Unfortunately, we also had some Kelly controller issues at high currents. Surprise...
My advise is this...Absolutely run this motor. Don't run a Kelly. We ran it because Kelly is the only company who had a controller with our specs and who would pay us any attention. Oh, also, while the super shiny motor looks great, it isn't so good for heat transfer. We sandblasted the can and it lowered motor temps several degrees with absolutely no other changes. It is definitely worth it to do this. I'll post pictures up when I can.