External controller for Kollmorgen motors

[Lance N]

Can anyone recommend an external controller for the Kollmorgen 300-400 watt motor?

I made a kid kart to use this motor. To make a long story short me and my test driver wound up toasting the internal controller.

I tried using a model aircraft controller and it sort of worked but has trouble with a standing start.

 

[vanilla ice]

Any standard sensored brushless controller should do. Tricky part is figuring out the wiring, but theres a few posts here to help with that. The Koll's break above 48v so something 36 or 48v would be perfect.

 

[spike]

I've used Crystalyte and E-Crazyman controllers. The wiring is not guaranteed to be the same even if the brand is, but here's a start...

http://endless-sphere.com/forums/viewtopic.php?f=2&t=173&p=1656&hilit=+uspd+external+controller#p1656

http://endless-sphere.com/forums/viewtopic.php?t=4696

http://video.google.com/videoplay?docid=366332646555574705#

Cheers

Spike

 

[fechter]

Right, the Kollmorgen can take up to 48v. The rotor flies apart at 60v.

Around 30 amps would be the most I would feed it. Even then it could get pretty warm. It can take around 50 amps for a few seconds.

 

[Lance N]

Thanks guys.

I'm running this thing on 24v. Will the controllers you recommend work at this voltage? I have a feeling they won't.

 

[spike]

Thanks guys.

I'm running this thing on 24v. Will the controllers you recommend work at this voltage? I have a feeling they won't.

You can get controllers that run from 24V-72V. However, if you are planning to run it at 24V you're best off buying a 24V controller just to be sure.
The only reason I can think for you to go for 24V would be if you can't afford more batteries. The motor works OK at 36V but is best at 48V.
Either way, Keywin will sell you a motor controller that will work at any of those voltages. Look him up under e-crazyman on ebay. A trusted vendor.

HTH

Spike

 

[bzhwindtalker]

I did not burn mine yet, even feeding it with 28v a123 at 60+amps... It gets pretty hot, when I'm lazy and don't pedal at all.
But my mounting plate act as a big dissipator, may be helping. I'm regularly pushing the thing 1.5kw, 1kw continuous.
It's a really good motor, but after 1 year of abuse, it starts to fall apart. the shaft needed to be soldered to the stator because the stator was freespinning :lol:

 

[Lance N]

This is driving me crazy.

There's a method to my madness regarding the voltage. I want this thing to top only out about 15 mph and I want a long run time. I bought a pair of Deka 32ah AGM batteries for about 60 bucks each. I bought them locally so I didn't have to pay for shipping. I was trying for the most run time for the least money spent. I figured I would just buy another battery if I wanted more speed. Right now though I have major budget restraints and can't just keep throwing money at this.

Do you guys think this controller will work?: http://cgi.ebay.com/24V-250W-brushless-controller-for-E-bike-scooter_W0QQitemZ260511665573QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item3ca7b48da5

It's rated at only 250w but maybe it will be ok on 24v.

I also found this: http://cgi.ebay.com/ebaymotors/350W-E-Bike-Brushless-Hub-Motor-Hall-Sensor-Controller_W0QQcmdZViewItemQQhashZitem1c0cb61ffdQQitemZ120472346621QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

I really, really appreciate your help with this. My two guys too, and the six other neighbor kids as well. They ask about the kart every day.

 

[spike]

Yes. Either of those should work. 250W is a bit weak but for a kid kart that might be a good thing.
I think the original Kollmorgen controller was 400W so the 350W controller would be a closer match.
You probably know this, but the extra watts won't make it go any faster, just adds more torque.
If you send e-crazyman (Keywin) a message he'll probably do a 350W version for the same price.

Also, remember you will need to add a throttle to match the new controller + male/female connectors for the throttle & halls.
Another alternative if you want to stick at 24V is just to replace the motor. I think they cost between $125-150 just for the motor.

HTH

Spike

 

[spike]

It might be quicker and easier to just buy this motor http://endless-sphere.com/forums/viewtopic.php?f=9&t=16229 ?

 

[Lyen]

Thanks guys.

I'm running this thing on 24v. Will the controllers you recommend work at this voltage? I have a feeling they won't.

The built-in controller is already 24v ready. I do not see any reason why you want an external controller if there is already one in there. Please explain. Thanks!