ALL NEW 150V-30A XieChang CONTROLLER

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ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 29 2010 7:27am

ALL NEW 150V-30A XieChang CONTROLLER
EB212-AS-1_low-res.jpg
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High Resolution Picture

Keywin tested this prototype controller before shipping.
148 Volts and 25 Amps continuous loading for two hours.
Mosfet heat sink temperature never exceeded 85 C.

Some potential enhancements ...
100 C Over-Temp Shutoff Thermostat

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Doctorbass » Apr 29 2010 9:50am

Knuckles wrote:ALL NEW 150V-30A XieChang CONTROLLER
EB212-AS-1_low-res.jpg
High Resolution Picture

Keywin tested this prototype controller before shipping.
148 Volts and 25 Amps continuous loading for two hours.
Mosfet heat sink temperature never exceeded 85 C.

Some potential enhancements ...
100 C Over-Temp Shutoff Thermostat

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Great Work!

Seem excellent choice for a 5306! and very high efficiency system!

It is using the IRFB4115?

Steveo did a 24 mosfet version he want to test at 100A 150V.. .. or it might be 50A?

Thanks for posting!

Will you release a higher current version?

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Ypedal » Apr 29 2010 10:41am

Price tag ?
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 29 2010 11:16am

Doctorbass wrote: Great Work!
Seem excellent choice for a 5306! and very high efficiency system!
It is using the IRFB4115?
Steveo did a 24 mosfet version he want to test at 100A 150V.. .. or it might be 50A?

Thanks for posting!
Will you release a higher current version?
Doc
Thanks Doc,

I was actually surprised when Keywin told me there was a new 12-fet w/ the on-board switching circuit.
And Keywin did an excellent job on fabrication. More controller pics in this web directory … http://98.131.176.65/EB212-AS-1/
Yes this unit is using the 150v irfb4115 mosfets. Refer to the high resolution link in my post.
No reason not to up the amps to 50 Amps max. Simple software flash. The wires are only 13AWG so they will get warm however.

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 29 2010 11:26am

Ypedal wrote:Price tag ?
Funny,
I really don't have 150V-50A bat setup right now (on my ToDo list).
And this was just a prototype for FUN. :roll:

But if someone wants to buy this unit (after I am done testing and maybe tweaking) I'll provide a low-ball price.
I am really hoping for someone to kick the hell out of it. Just send me a PM.
I can get many more units as I have surplus 4115 fets at Keywin's shop.

This first one does not have a CA connector.
I will put 45A PP connectors on phase/bat wires.
And post more pics.

I am also waiting on my 100C thermostats ...
http://cgi.ebay.com/67L100-Switch-Tempe ... 2eac160fa9

And I also want to put an easy FJP9100 transistor mod in front of the switcher circuit ...
I'll explain the logic of that later in this thread.

btw ...
I picked up these cool little adj. switchers from Keywin.
This was before I knew the 12-fet had an on-board switching circuit.
But these might be useful in all kinds on neat applications ...
Lil_Switchers.jpg
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by dnmun » Apr 29 2010 12:55pm

!this is great!

and the switchers are really put together just right.

can you read the linear part#? is that the 2596? is it 60V ?

he uses a 10k cermet trimpot for the feedback for the voltage output, so that could be fixed value too.

for more current output, maybe solder something on the tab to add more heatsink.

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 29 2010 2:24pm

The lil switcher module is based on the 150kHz LM2596-HV … 60V(in) max
http://98.131.176.65/EB212-AS-1/LM2596.pdf
unit spits out ANY VOLTAGE (adj the POT)
I have yet to play with it.
(On my ToDo list)

Keywin gets them off of taobao (cheap) …
http://item.taobao.com/item.htm?id=3139287422

I want to integrate the FJP9100 transistor into them to boost the max voltage input
well beyond 150v (depending on the milliamps needed).
Might be a cool way to build 150V 25A mini 6-fet monster controllers. :shock:
Same for irfb4110 6-fet units at 100V.

But heck … We can get tons of these.

LOL … Keywin is my A#1 toabao agent. :D

Very Cool. 8)

PS They also have this model with a heatsink glued to the bottom of the mini pcb ...
It's on taobao somewhere ... I'll find it again ... Here it is ...

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Last edited by Knuckles on May 05 2010 8:53pm, edited 1 time in total.
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 29 2010 5:09pm

LOL ...Keywin is my buddy ...
BUT ... What is WRONG with this picture? :roll:
Whats_Wrong.jpg
Whats_Wrong.jpg (115.94 KiB) Viewed 4314 times
I will fix it of course.
Special price discount for the first poster who knows the answer.

:mrgreen:
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Ypedal » Apr 29 2010 5:40pm

:?:
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 29 2010 6:20pm

NOPE!
He Forgot to solder the + trace to main Cap C202


:lol:
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by tostino » Apr 30 2010 3:35pm

I just received 2 of the boards from him without fets ;). Caps all in place, but i'll need to put in fets, probably adjust resistor values, and run all the wires!

This is super exciting.

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Arlo1 » Apr 30 2010 4:06pm

Price??????????????????
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » Apr 30 2010 4:43pm

Well ... This is an "E-Bike Reviews & Testing" thread.
I'll post "For Sale" in the market place.

But $150+shp is a good ballpark number for a "plain vanilla" 150V 12-fet unit.
IMHO

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Re: ALL NEW 150V-50A XieChang CONTROLLER

Post by Knuckles » May 05 2010 6:05pm

Well I finally got it all together. I re-flashed the MCU and set the amps to 50A.
This unit came with a precision R12 mod from Keywin so double the software values for LVC and Regen.
I set the software LVC to 18.8V which is a real LVC = 2 x 18.8V = 37.6V.
I set the software Regen to 75V which is a real Regen = 2 x 75V = 150V.
I added the PowerPole connectors and an extra e-Brake connector.
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150V50A.jpg
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Here is a screen shot of the software flash settings.
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150V50A_software.jpg
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The ignition voltage regulator circuit modifications are shown here.
Note the thermal switch on the mosfet. The switch opens at 100 degrees Celcius.
Also note the FJP9100 high voltage transistor mod. The transistor mod is real simple.
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12-Fet_MOD_1.jpg
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A close up shot of the transistor mod.
The transistor drops the voltage down to the on-board switching circuit.
The switching circuit really isn't designed (by XieChang) to take 150 volts.
The transistor mod makes for a much longer safer controller life.
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12-Fet_MOD_2.jpg
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Real simple to build.
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12-Fet_MOD_3.jpg
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And the bottom of the board.
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12-Fet_MOD_4.jpg
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I added a PVC sheet for electrical insulation but cut an area out for the resistors to shed heat.
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12-Fet_MOD_5.jpg
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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.
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All_Ready.jpg
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So I guess it's time to start selling these things. I'll add a CA connector on the next unit.
Also very easy to change the LVC if needed.

Bad-Ass testers are welcome. I'll post in the "For Sale" section next.

-Knuckles
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Re: ALL NEW 150V-50A XieChang CONTROLLER

Post by Knuckles » May 05 2010 8:37pm

Parts are cheap for the VR_Mod.
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VR_Mod_Parts.jpg
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Last edited by Knuckles on May 06 2010 5:23am, edited 1 time in total.
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by dnmun » May 05 2010 10:59pm

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.

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Re: ALL NEW 150V-50A XieChang CONTROLLER

Post by Knuckles » May 06 2010 4:48am

I don't plan on beefing up the original traces,
just the small trace that goes to the Cap C202 ...
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Pre_Mod.jpg
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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 :shock:
I am sure that would melt a 9C motor! :D

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).
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R10_11_12.jpg
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I might need to address these two issues also for true 150V operation.
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » May 22 2010 1:47pm

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! :D
So it looks like the 6-fet THRU 36-fet controllers will ALL have the on-board VR circuit!

NICE! 8)
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » May 24 2010 3:04pm

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by etard » May 24 2010 3:52pm

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.
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by dbaker » May 24 2010 5:57pm

Knuckles,

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

Dave

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » May 24 2010 6:38pm

dbaker wrote: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! :lol:

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). 8)

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.
Last edited by Knuckles on May 24 2010 9:26pm, edited 1 time in total.
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » May 24 2010 6:49pm

etard wrote: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!) :mrgreen:

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.
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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by deVries » May 27 2010 12:44am

Knuckles wrote:
6-fets = 25 amps
12-fet = 50 amps

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

:lol:
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? :P

Thanks!

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Re: ALL NEW 150V-30A XieChang CONTROLLER

Post by Knuckles » May 27 2010 10:00am

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

:lol:
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? :P
Thanks!
Mod away my friend. Also check Lyen's offering here ... http://endless-sphere.com/forums/viewto ... 31&t=18214
And review this post by mwkeefer ... http://endless-sphere.com/forums/viewto ... =0#p272438

-K
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