Page 6 of 6

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 10 2019 4:36pm
by John in CR
Even just one on that back end plate would do a lot of good just by getting the hot air out of the controller. Since there was nothing to get hot on the bottom of my boards, I blocked that off as a path for air to flow to help focus flow where it was needed most. These days, since I use 6 phase motors, I don't need super powerful controllers, so I run them stock and at conservative settings. 100A each from the battery with less than 2:1 phase/batt current limits at voltages from 74V nominal to 115V nominal is typically plenty...especially since I have the modded MadAss running at 30kw+ peak input for thrills.

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 10 2019 6:58pm
by shaman
John in CR wrote:
Mar 10 2019 4:36pm
I use 6 phase motors
Where does one get those 6 phase motors?

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 11 2019 12:25am
by ElectricGod
shaman wrote:
Mar 10 2019 6:58pm
John in CR wrote:
Mar 10 2019 4:36pm
I use 6 phase motors
Where does one get those 6 phase motors?
Depends on the power you want...

John is talking about hubmonsters. He has several of them, but they are not cheap. I have 2 of them. It took looking in local for sale sites a long time to find them on existing electric mopeds.

Just about all Motenergy axial flux motors are dual stator or 6 phases. Again not inexpensive.

You can take any outrunner and wind it for 6 phases. I have an Alien Power 12090 that's burnt out. I'll eventually get around to winding it for 6 phases.

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 12 2019 12:28pm
by Philaphlous
Well it's definitely not going to be waterproof or water tight with those fans... After a 14mi ride on my controller pulling anywhere from 600-1500w...more around 650W consistently I had absolutely no heat from my controller. Pretty amazing! Well see what happens when it's 90F out but I'm not worried at all pulling 2K through mine. I also added new thermal paste to the mosfet heatsink block.

I better be seeing wheelies from this controller!

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 12 2019 4:06pm
by ElectricGod
I posted back a few pages in this thread about losing a few mosfets in the controller. I was running an Alien Power 12090 when it happened.

A couple of days ago, I connected that exact same motor again and sure enough, popped mosfets again. Grrr!

Back a few months, I assumed there was a couple of weak mosfets...it happens form time to time.

I took the 12090 apart and found I have a partial phase short to the stator. The motor is effectively brand new as it's never seen more than bench use. This is why I'm blowing mosfets. There's no evidence that a motor phase is damaged.

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 20 2019 4:08pm
by Philaphlous
So from your extensive experience with modding the controller where do you see the weakest link to be? I'm considering adding a little more solder to the shunt for 55-60A on mine... Im thinking the 14-16awg phase wires going into the motor that are only about 6" long won't like those phase amps...

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 21 2019 8:14am
by ElectricGod
Philaphlous wrote:
Mar 20 2019 4:08pm
So from your extensive experience with modding the controller where do you see the weakest link to be? I'm considering adding a little more solder to the shunt for 55-60A on mine... Im thinking the 14-16awg phase wires going into the motor that are only about 6" long won't like those phase amps...
Are you talking about the 12 fet PV controller or something else? No PV controller uses 14 or 16 awg wires anywhere.

Adding solder to the shunts...
just don't. If you want more amperage do it right and use better shunts.
Also, if you are using a PV controller, this is the wrong way to go about doing things. These controllers are fully programmable.
"buttering up" shunts is what you do to cheap Chinese dumb controllers that you buy on ebay for $40.

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: Mar 26 2019 4:09am
by Philaphlous
ElectricGod wrote:
Mar 21 2019 8:14am
Philaphlous wrote:
Mar 20 2019 4:08pm
So from your extensive experience with modding the controller where do you see the weakest link to be? I'm considering adding a little more solder to the shunt for 55-60A on mine... Im thinking the 14-16awg phase wires going into the motor that are only about 6" long won't like those phase amps...
Are you talking about the 12 fet PV controller or something else? No PV controller uses 14 or 16 awg wires anywhere.

Adding solder to the shunts...
just don't. If you want more amperage do it right and use better shunts.
Also, if you are using a PV controller, this is the wrong way to go about doing things. These controllers are fully programmable.
"buttering up" shunts is what you do to cheap Chinese dumb controllers that you buy on ebay for $40.
Yea I got one of those cheap ass controllers your talking about. It does have soldering points for a plug to program it but those aren't used at all.
It's kinda strange though that the controller doesn't really even get warm... Maybe it's just in such a great location on my bike? It's behind the downtube between the rear wheel and downtube. It gets airflow from the front and I believe also some from the wheel.

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: May 08 2019 4:57am
by j bjork
Interesting thred :wink:

Has there been any progress with this project?

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: May 12 2019 4:49pm
by ElectricGod
j bjork wrote:
May 08 2019 4:57am
Interesting thred :wink:

Has there been any progress with this project?
No much...until a couple of days ago. The AP 12090 with the shorted phase blew up the controller. I've had many things on my plate recently so this just sat. I got it pulled apart a couple of days ago and found that 10 of the 12 mosfets are cooked. I've replaced all of them, but need to test it out now.

That was a lot of money on new top end mosfets that lasted just minutes! GRRR!

Re: Epic 7kw+ 12 fet controller...or there abouts :)

Posted: May 14 2019 12:45am
by ElectricGod
Well that controller is a lost cause...
Not only were the mosfets toast, but the control electronics were fried too. That Alien Power motor really messed things up badly!

I have another of the 12 fet PV controllers. Last night, I got it mostly modded. The 8 awg wires and big shunts are added. The phase busses still need some beefing up. I'm going to rework my copper heat spreader a little before installing it in the beefed up shell.