I think anyone using an HV Series Castle Esc on an Ebike should seriously consider adding higher capacity caps. Most of the following information is posted in the "High power RC motor and drive unit production" thread but thought it should be posted in a separate thread to help make sure as many people as possible have the information necessary to avoid blowing HV Series Controllers.
I got the following from Matt's build description on the bottom of this page:
http://www.wisil.recumbents.com/wisil/s ... mbent2.htm
and:Last I removed two of the eight 180mf caps and added two 1,000mf caps in their place effectively increasing the capacitance from roughly 1,000mf to 3,000mf.
Then I sent Castle this quote by Matt from another post in an email (excerpt):I need to make it abundantly clear that this ESC issue is related to my use of the huge Plettenberg motor under hard acceleration. I have never run into anyone else blowing HV110s in bike use. So, please do not assume the HV110 is inadequate! I have merely been pulling 7,500 watts through a 5,500 watt controller. So, this is my solution.
Even though I saw that and sent a copy to Castle I still had the impression the caps were required because he was running 7kw through the Esc. Then I received their response:I just spoke with Castle Creations. The SHV200 is being released soon, however, the entire first production run is sold out. Second run is scheduled for 3 to 4 months from now. That stinks. But, I have found the HV110 to be fantastically stable if added capacitors are used on the input side. So, for anyone looking for up to 4,000 watts at 50 volts or less, an HV110 (with input caps added) is the most cost effective choice anyway.
When I posted the above Matt's response was:An HV110 will handle 2-3kw fine, but you would have to add extra caps as recommended. The ESC is meant to start an airplane motor...not a person on a bike.
I hve run the HV110 up at 4kw with my AXI and had no issues. But, at 4kw on my Pletti, I had issues after 200 miles. I wondered about that and asked Castle about it. They said there were a number of issues that contributed to my controller failures. When I asked about extra caps, they basically told me I would be masking a problem by adding caps. Hmm, if that is the case, why do these ESCs have caps to begin with? "Oh, good point, yes I guess extra caps would help...." So, since running extra caps, I have had no problems. I also experimented with my slipper clutch to keep from overamping the controller. However, I still blew one controller just limiting my amp pull to under 3kw max. The caps made all the difference. Maybe I will become a dealer and stock a few cap modded HV110s for EV use.