Reliable controller options for sub 3kw

[Lurkin]

I am in the process for figuring out the winning combination for the next ebike.
However, I'm getting a bit stuck on the controller options. I have decided on dd leafmotor either 1000w or 1500w and a Flux Beta frame.

I want to be able to access decent information - battery pack balancing prefer, limiting based on distance etc. It also MUST be reliable - in cycling terms NOT ebike terms. It will be used for commuting 80km a day - it cannot fail on the way.

It seems the options are:-
Adaptto emini - seems to meet the brief and has greater functionality than anticipated or required. Room to move up on power if required. Provides really good compatibility with BMS and it's own display, really like the pack and charging features. The only thing holding me back is the owners thread seems to have a lot of emini fails in it.... Can a Maxe be used at low power well?
Infineon controller from Em3ev + CA - can be combined with analogger for more data download. Isn't much cheaper than an emini after freight.
Lyen 6 Fet controller + CA - awesome size wise, not sure about reliability. Tempted to copy Kepler's idea of using it without a case and the frame as a heatsink. However, probably requires greater knowledge of the inner workings of CA to get it to work well - which I don't have.
Random cheapo chinese controller + CA - cheapest option but may lack in functionality and reliability.
Lebowki style homemade + CA - not cheap but most educational. Would like to do this anyway in the long run, reliability being the reason it's no good now.

At this stage I really want an Adaptto emini.. just a little worried about having to send it back to Russia for warranty problems if there are any. Price is really the last consideration - I want this to work and work well.

Can anyone think of other ideas?

 

[bowlofsalad]

I am in the process for figuring out the winning combination for the next ebike.
However, I'm getting a bit stuck on the controller options. I have decided on dd leafmotor either 1000w or 1500w and a Flux Beta frame.

I want to be able to access decent information - battery pack balancing prefer, limiting based on distance etc. It also MUST be reliable - in cycling terms NOT ebike terms. It will be used for commuting 80km a day - it cannot fail on the way.

http://www.ebikes.ca/c-phaserunner.html Might work? Potted controller, might be more reliable.
Cost is the least concern? Why not buy two adaptto mini-e's, keep them both at the same settings, practice swapping, always leave with an extra 20 minutes. Keep spares of everything, practice swapping components regularly, inspect often, know that nothing is infallible.
Need to keep the fets cool? A coolant loop to a radiator will wildly outperform anything, no contest. Need even more performance from a radiator? Keep a temperature controlled fan on it, fets on ice.

 

[Lurkin]

The reason for not wanting two is the admission of doing it is because its unreliable. Further, if it does fail, it's unlikely to be where the spare is.

My current ebike would get an inspection and clean weekly - every 400km, where I would check if anything's weird or requires servicing.

 

[bowlofsalad]

The reason for not wanting two is the admission of doing it is because its unreliable.

It sounds like you are saying that you'd rather just buy one really reliable controller rather than two unreliable controllers, but the phrasing is very odd. But if I am correct, I am saying buy two reliable controllers and know that nothing is impossible to break. I've read a lot on these forums and looked around to a great degree, but nothing I've heard of or used is thought of as flawless, some better than others, but you already seem to have a decent idea on that front.

It's hard to say with an extreme degree of certainty what is and is not reliable. There is no repository for information or large scale poles where 1000s of people under similar conditions can proclaim how things worked out for them. The closest I know for who might have some heavy degree of insight are those who make, sell and repair multiple brands of e-bike controllers. The only person I know of like this is Justin of ebikes.ca, who put together the phase runner controller.

I should also note, you might also benefit from focusing on keeping your ride as soft as possible. What I mean by this is high air volume tires with suspension. Each knock and bump sends vibrations through everything which is certain not to lengthen the life of those components you are worried about failing.

So in summation, a soft ride with redundancy is probably your best bet to a high degree of certainty for reliability. You might keep the spare controller mounted beside the other.

 

[wesnewell]

Over 4 years ago I bought the cheapest 72V 1500W 40A 15fet controller I could find for <$35 shipped. I'm still using it today after ~15k miles, running it on 24s lipo charged to 100.8V for over the last 3 years.. A higher price will not guarantee more reliability. And I sure as heck wouldn't run a 6 or 9 fet controller over 25A and expect it to be reliable.

 

[cwah]

Sabvoton are more reliable but more chunky

 

[Lurkin]

I have considered a cheap controllers as I have read your comments before. However, they lack the functionality of the adaptto and it appears they usually require modification to use a CA with, which may reduce reliability again given I'm not confident on that front. Besides, I can have any voltage I want given I will be making a custom 18650 pack anyway.

I'm not taking a backup controller with me, there won't be room for it and as previously noted, I would only do that if I didn't trust what I had bought. If I have that little trust in it, I would not buy it in the first place.

I will look more into Sabvoton controllers, although space is at a premium.