Shenzhen (ecrazyman) Controller Information

[oddjones]

OddJones,

Sorry about the stupid post that I deleted. If you actually rode it, however slowly, the motor is mounted on the bike in the proper direction. Yes is should freewheel when you spin it forward (that's like you are coasting along or pedaling only, so you don't want the motor resistance).

Thank you for this! - I've figured this, but when you get stuck in a gumption trap like this you start questioning everything you haven't got a definitive answer for!

Now to your problem. Am I to understand that you have it running fine with good speed and the motor sounding nice and smooth at all speeds, but it needs a little backward roll to get the controller to kick in? If so, then it sounds like your initial ride with the incorrect wiring did some damage to the controller. When an electric motor is sounding like the "crack of doom" and you keep going until "it made a really ugly noise and the motor cut completely", then I would consider you to be very lucky if you didn't damage at least the controller by riding it with the wires connected incorrectly.

Ahem... yeah Trouble is, this was my first time with a setup- I've not seen an e-bike in action yet - so I didn't know whether the battery worked, the controller worked, the throttle worked, how fast it should go... any of it. I also didn't know what a proper motor should sound like - it just sounded to me like (loud!) "graunchy gears" - I knew it was a geared motor and in the absence of any instructions had wired it up like I thought it should be - it's only now that I've tried 72 different combinations of Hall/phase wires that I know all the noises a geared hub motor can make and what it should sound like - One thing I definitely propose should come out of this whole story is a "Getting Started" section easily accessible on this forum so people like me don't clog up technical threads with issues like this - and more importantly hopefully learn from these mistakes!

If it's now running well and spinning the wheel forcefully, the the wiring sounds correct, but that little backwards roll requirement is saying that it first needs a magnet to pass a hall sensor to get going. Something is definitely wrong. My guess would be that you fried something in the controller. Since it still works at all, then it's probably something small. My suggestion would be to get with Knuckles and explain the symptoms and history to get the problem diagnosed, and get you riding. If it "goes great guns" with the motor no ragged noises, only the whirring of the gears, then the wiring sounds correct, so I hope you made note of the combination. Don't spend a bunch of time going crazy with wiring combinations until you have a diagnosis.

Agreed - I've got a spreadsheet full of working combinations(!) ... Knuckles?

Good Luck with it. All the frustrations will make it all the more sweet once you get it running properly. On my first ride with a hub motor, I made it less than 10ft before the dropouts snapped and the axle spun breaking the wiring harness, and I thought I had sufficient torque arms, so if it's just the controller you got off easy. I don't see torque arms on yours, and with a front geared hub that's just begging for a serious accident.

I've heard lots of mentions of torque arms on this forum, but I've not seen a picture or any links to where I might get hold of them? - this is a BIG forum with lots of posts to read - maybe a suggestion for the "getting started" section would be a glossary?

John - thank you so much for taking the time to read through my tribulations and come up with such a thorough answer - it's just what I needed - I woke up this morning thinking "Have I got to send my motor back to China?" (It took 2 months to get it here) - now I have a plan - starting with some PMs

Thanks again,

Dom.

 

[mikereidis]

Has anyone tried the "new 2008.8" 48v/600w unit yet ? : http://cgi.ebay.com/48V-600W-brushless-controller-for-E-bike-scooter_W0QQitemZ300248682281QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#vi-content

What about 72v/1000w: http://cgi.ebay.com/72V-1000W-brushless-controller-for-E-bike-scooter_W0QQitemZ300252066646QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

I'm more interested in 72volt model.

So price is cheap but shipping is high ? 72volt model says $32 but $36 shipping/handling.

Thanks !

 

[fechter]

Has anyone tried the "new 2008.8" 48v/600w unit yet ? : http://cgi.ebay.com/48V-600W-brushless-controller-for-E-bike-scooter_W0QQitemZ300248682281QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#vi-content

What about 72v/1000w: http://cgi.ebay.com/72V-1000W-brushless-controller-for-E-bike-scooter_W0QQitemZ300252066646QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

I'm more interested in 72volt model.

So price is cheap but shipping is high ? 72volt model says $32 but $36 shipping/handling.

Thanks !

Those are the new "Infineon" controllers. See http://endless-sphere.com/forums/viewtopic.php?f=2&t=5713

 

[Knuckles]

So are you running?

If not then post. If so then post.

The fix is so easy. Been there done that.

-Knuckles

 

[Knuckles]

Has anyone tried the "new 2008.8" 48v/600w unit yet ? : http://cgi.ebay.com/48V-600W-brushless-controller-for-E-bike-scooter_W0QQitemZ300248682281QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#vi-content

What about 72v/1000w: http://cgi.ebay.com/72V-1000W-brushless-controller-for-E-bike-scooter_W0QQitemZ300252066646QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

I'm more interested in 72volt model.

So price is cheap but shipping is high ? 72volt model says $32 but $36 shipping/handling.

Thanks !

I have the 72V Infineons. Order them thru me. $125 (+$9.50 shp in USA only) for ES members.
Also see my ebay. http://search.ebay.com/_W0QQsassZrobertn8094

Outside USA contact ecrazyman@gmail.com But I am always here to help. Worldwide.

btw ... Keywin is discontinuing that 1000W 72V (old pcb). We are strictly (new pcb) Infineon at this point.

-K

 

[John in CR]

...The fix is so easy. Been there done that.

-Knuckles

Please do share. Some of us are still running this controller. I want to know in case it ever happens to me.

John

 

[mikereidis]

Has anyone tried the "new 2008.8" 48v/600w unit yet ? : http://cgi.ebay.com/48V-600W-brushless-controller-for-E-bike-scooter_W0QQitemZ300248682281QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#vi-content

What about 72v/1000w: http://cgi.ebay.com/72V-1000W-brushless-controller-for-E-bike-scooter_W0QQitemZ300252066646QQihZ020QQcategoryZ11332QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

I'm more interested in 72volt model.

So price is cheap but shipping is high ? 72volt model says $32 but $36 shipping/handling.

Thanks !

I have the 72V Infineons. Order them thru me. $125 (+$9.50 shp in USA only) for ES members.
Also see my ebay. http://search.ebay.com/_W0QQsassZrobertn8094

Outside USA contact ecrazyman@gmail.com But I am always here to help. Worldwide.

btw ... Keywin is discontinuing that 1000W 72V (old pcb). We are strictly (new pcb) Infineon at this point.

-K

But I'm in Canada. Where we have beavers, skunks, cats and rabbits to dodge on the bike trails (all 4 last night), and wonderful $100 Canadian Tire Yardworks LiMn 20v, 6ah batteries you can't get in US.


Fechter said "Those are the new "Infineon" controllers." Perhaps you are both right and ecrazyman doesn't have new revision 72v/1000w 2008.8 controllers yet ?

Does Keywin = ecrazyman ? The XLyte 72v/20a controller I thought was dead is fine; just too much inrush cap current for my BMS which I can work around, so my controller buying pressure is off, but I still want another controller with instant start.

Thanks...

 

[Johnbear]

Below are the results of my ecrazyman to golden motor connection

I was running a 36v and 24v nicad packs in series for 60v total.

My max amps was 25.15 probably due to my voltage being lower than the 72v max.

My wiring was

Knuckle-troller to Golden motor (edited)

Hall sensors-

Blk Blk
Red Red
Yel Yel
Grn Blu
Blu Grn


Controller - Motor
Yellow- Yellow
Green - Blue
Blue - Green

Runs pretty smooth. The attached pictures are the motor under load (edited)

 

[gip_mad]

By "max amps are 25" you mean with you on the bike, right? Not with the wheel spinning free?

 

[abhimanyu]

spinning free @ 25 amps!!!...omg....

i guess its with him on the bike

 

[gip_mad]

spinning free @ 25 amps!!!...omg....

i guess its with him on the bike

It could happen with a bad phase wires combination... That's why I asked!

 

[Johnbear]

That is on the bike load. The phase wires seem to be ok, It runs very quietly and smooth. The no load amperage is around 1. So far so good!

 

[Knuckles]

Please ...

If anyone needs help with the Bafang Motor just PM me. I am here to help.

Same goes for any controller that Keywin and I sell (New Infineon or the original crazy controller).
The original crazy controller is described in the first post of this thread by fechter

The Infineon controller is brand new and solves the PUMA/BMC problem and can run any BLDC motor to very high rpm.

Also ... I posted on the wiring solution long ago, so did fechter.

Just follow my instructions here and it WILL ALWAYS WORK PERFECT!
http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484#p81888

cheers,
Knuckles

Does Keywin = ecrazyman ?

Yes. Keywin Ge is a good Chinese Engineer dude in Shenzhen China (and my good friend and partner) ... his email is ecrazyman@gmail.com (Ha Ha ... He So CRAZY!)
Me? I am Knuckles (Bob) and I am CRAZY USA Engineer Dude in New F'n York! (Ha Ha I really CRAZY). But I know these controllers inside and out.
My email is rnich01@optonline.net ... Email or PM me anytime with any problem. I'll help you out.
(My english is better but Keywin is way better at being Chinese than I am! I am Irish-Swede surfer dude)

I WANT EVERYONE RIDING EV!

8)

 

[gip_mad]

Just follow my instructions here and it WILL ALWAYS WORK PERFECT!
http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484#p81888

You should ask fetcher to post this link on the FIRST post in this topic, so new guys (and us when they ask for it) doesn't have an hard time finding it... :wink:

 

[Knuckles]

Just follow my instructions here and it WILL ALWAYS WORK PERFECT!
http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484#p81888

You should ask fetcher to post this link on the FIRST post in this topic, so new guys (and us when they ask for it) doesn't have an hard time finding it... :wink:

What a great freakin idea!

Oh please "Great Fechter - Ruler of thy ES Realm" ... Thou please grant us this wish! Thou newb surfs beg thee!

 

[fechter]

It is done...

 

[Knuckles]

LOL :lol:

toa chie!

Circle is now complete!
http://endless-sphere.com/forums/viewtopic.php?f=2&t=4282&st=0&sk=t&sd=a#p63429

Oh please "Great Fechter - Ruler of thy ES Realm" ... Please end'eth this freakin thread! Thou humble servant (Freakin Knuckles) beg'eth thee!

Old controller is now "crap" compare'est to thy servant's new Infineon. Please! I beseech thee! End'eth thine torment.

Begin'eth new thread! (Is begin'eth a freakin word?)

Knuckles

 

[fechter]

OK.

Which thread do you want to continue with? I will de-stickify this thread and it will drop off into the archives.

 

[solarbbq2003]

Hi Knuckles bob,
v2 crystalyte controller with modified board can also run bmc motor at higher rpm, in V2 thread I reported test results
57volt ( 48v nominal) cobalt oxides rotor speed 2,389 max ( 637Hz )
85volt (72volt nominal) cobalt oxides rotor speed 3398rpm max ( 906Hz )
that was for 500watt bmc hub style motor ( puma )( 320rpm@36v version) is it possible to get some data on rotor speeds your getting would be interesting to compare max rpm at similar voltages for two different controllers.

 

[Knuckles]

OK.
Which thread do you want to continue with? I will de-stickify this thread and it will drop off into the archives.

Just start an Infineon thread. You have one now. Plus Keywin will send you the 18 fet "PSYCHO" version if you want. :wink:
Heck ... Like I have a clue. But that old pcb is history (but I will always offer support). So do what you think is best for the ES community.



Gosh! Why is this controller so long?

 

[Knuckles]

Hi Knuckles bob,
v2 crystalyte controller with modified board can also run bmc motor at higher rpm, in V2 thread I reported test results
57volt ( 48v nominal) cobalt oxides rotor speed 2,389 max ( 637Hz )
85volt (72volt nominal) cobalt oxides rotor speed 3398rpm max ( 906Hz )
that was for 500watt bmc hub style motor ( puma )( 320rpm@36v version) is it possible to get some data on rotor speeds your getting would be interesting to compare max rpm at similar voltages for two different controllers.

This is cool. I really respect Justin so I am always courteous.

Let the controller Wars begin! 8)

[youtube]U4uC4UcfiTg[/youtube]

 

[gip_mad]

This thread should remain sticky, it's very useful, there are a lot of these controllers still around!

 

[solarbbq2003]

can anyone verify if infineon controllers have been tested with bmc 500watt at 48volt or higher and if they are handling the higher rpm switching speeds?

 

[fechter]

can anyone verify if infineon controllers have been tested with bmc 500watt at 48volt or higher and if they are handling the higher rpm switching speeds?

Yes, I tested with a BMC motor and was unable to hit any limit up to my maximum of around 56v. Others have tested up to 72v.

 

[solarbbq2003]

excellent news
seems there is a new model xie chang also, XQL-XC500