Do controllers have overheat protection?? Re: Cyclone contro

[PJIII]

I would like to know if controllers in general have overheat protection where they shut down & specifically whether or not a CYCLONE controller has it. I have a complete new Cyclone system--a 650 watt & the controller is remote to where I cannot feel it while riding. On one of my 1st test runs I had just climbed a steep bridge (I had climbed it earlier & was on the return trip & some time had elapsed--1/2 hour or so) came down the slope and traveled a few blocks & the system shut down. I never saw a yellow light but may have missed it. When it stopped I turned the throttle wide open & got a red light so I pedaled home. @ the time I was thinking the batteries were low so I put the charger on & much to my surprise the batteries were fully charged w/ 1-1/2 hours!!! (I did not think to feel the controller at the time---if it happens again I will) The other day, from a yellow light condition, I charged the batteries to full charge & that took 4 hrs. I have a 24 volt 6 amphr charger & am charging 2-24 volt 33 amphr SLA batteries for a total 66 amphrs @ 24 volts.

The next time I have a full charge I am going to take a voltage reading & the same when they are discharged to the yellow condition for reference.

I have felt the controller after a flat road ride & it is hardly even warm.

Any information and/ or comments would be greatly appreciated.

 

[heathyoung]

Yep. A 650W (external controller) - along with the internal controller versions - have a thermal sensor in the windings of the motors to protect them.

 

[PJIII]

Yep. A 650W (external controller) - along with the internal controller versions - have a thermal sensor in the windings of the motors to protect them.

So, if my suspicions that I experienced an overheat situation are correct, with the trike having 12 speeds via a 3pc Cyclone crankset & a 6 speed cassette, I think I'll try the bridges in my lowest gear.

I am doing range testing with various gearing & speed configurations so that I better understand this new build's capabilities and its weaknesses. I haul 4-33 amphr SLA batteries so I have #100 of extra weight to contend with. I would love to have LiFePo4's but cannot afford the $1,600 for the large ones and a charger as the build itself cost $2,000.00 so, for now, I have to make the best of what I have.

 

[heathyoung]

Wait. What? 66AH. Um... How far are you planning to go with this? With puekerts losses + extra weight, you could get furthur on a lot less AH than this - I get 30Klms from my 24V 20AH pack, beating it senseless. It cost very little to make as well.

 

[02jze]

What pack are you running heath..

 

[heathyoung]

Its in my sig. 16P6S Konions made from 14 Makita drill packs from DrBass - doesn't need balancing, as long as its not run too low. Didn't really bother matching cells, just made sure that they were all at the same SOC before paralleling. All fits on a rack mount bag, with room for the charger, weighs around 5kg.

 

[PJIII]

Wait. What? 66AH. Um... How far are you planning to go with this? With puekerts losses + extra weight, you could get furthur on a lot less AH than this - I get 30Klms from my 24V 20AH pack, beating it senseless. It cost very little to make as well.

I am just in the range testing phase & so far in an uncompleted test I have made 45.2 miles @ 8.5 MPH & batteries discharged to 23.91 volts with more miles yet to go. This test is on flat roads. Other tests will include climbing bridges and different speeds. I do know when the speed goes up the range declines & so it does when climbing grades but I have to test to find the trike's capabilities.

When I planned the build I was hoping for 16 to 20 miles w/ either one or two bridges included.---only testing will tell.

I am thinking of ordering a Watt's-up meter.

 

[PJIII]

I JUST finished the 1st range test. I got 75.41 miles until I got the red battery indicator light. Ending voltage is 22.1 Volts. Is this to much of a discharge state? What is a safe discharge level?

(edit)The recommended end-of-discharge voltage for the SLA is 1.75V/cell. Unlike the preferred flat discharge curve of the NiCd, the SLA has a gradual voltage drop with a rapid drop towards the end of discharge (see Figure 5-1).

 

[PJIII]

I BELIEVE this is good information that I can trust. What this is showing me is I discharged the batteries to about 30% once & that does not bother me.

Hello Mr. Tone,

Lead Acid resting State of Charge voltages 6 cells

12.65 V = 100%
12.45 V = 75%
12.24 V = 50%
12.06 V = 25%
11.89 V or less = discharged

Resting voltage is taken at room temperature and 12 - 24 hours after the completion of charging.

Tom