Steveo's Replica e-crazyman 133v Success!

[steveo]

Hey everyone!

I have been wanting to go back to my 100v setup for a while .. but i will need to build a new controller to do this....

I have a few videos ... this is originally a 48v controller (no load testing)

The purpose of this video what to check if any of the compents on the board would change voltages as i brought the controller voltages higher..

ps my camera cuts out at the end .. never fails to do so lol


http://www.youtube.com/watch?v=rJe7Yf2YkfY

http://www.youtube.com/watch?v=mYh7j1QYzXQ

http://www.youtube.com/watch?v=oD0UaU26CEg



- also i've tested the voltage regulators & resistors tempature after about 5mnis+ on standby ... everything between 45degress & 55 degrees (good)

-steveo

 

[steveo]

Update 2008-10-13

I've tested the controller at 75.9 nominal voltage of a123 @ 75 amps Controller has passed with flying colors..

-steveo

 

[steveo]

Hey Everyone

I here is an update on this controller

LVC MOD

I have discovered if you remove the r3 resistor & replace it with a 50k or 100k pot i have gotten the LVC to work

I have test the LVC with an 84v pack & my 66v pack & it is working !!

Speed Governer Mod

I have to post a picture of this; i don't remember the resistor number off hand

But if you replace the resistor found on the furthest bottom corner (wires side of the controller, infront accross from mosfets) with a 4.4k - 5k resistor * and by using the existing 50k governer pot this controller has I was able to get my speed to be governed to 24 km/h with just over 20amps draw max & my controller was able to provide 75amps @ 66v at full power

This Speed governer mod is better the the cycle analyst governer IMO

Yes, I believe so .. Unlike the cycle analyst which has a delay to cut the speed or reduce the aperage .. and again IMO cuts of hard with loss in power for second or seconds .. to stop at certain speed or aperage..
this mod allows the user to have a reduction in speed and & amperage at the same time & is smooth and no hard cutoff..

I hope this tread will get a little more attention then it has gotten till now ..

I have 4110's on the way .. this same controller at 100v will be my next modification.!!!!

thanks
Steveo

 

[steveo]

Hey Everyone

I HAVE HAD SUCCESS FINALLY!!!

-I have a controller operating perfectly on IRFB4110 mosfets (from mexico - real stuff)
-I'm using 3 470uf 160v capasitors
-Upgraded Power wires only from standard 12 AWG to 10 AWG
-Phase Wires Have been replaces with Exact same wiring used in the Crystalite controller 12 AWG full copper
-EST 70 amp shunt
-Voltage ran on fully charged A123 Pack 106v
-Voltage Sence wire ran at the 66v mark on my pack NOT the 106v mark!!!

other mods

I've added an adjustable LVC on R3 resistor 50kohms
Throttle on this controller has an adjustable 50kohms pot (to govern speed .. i have to post more on this ..)

Here are some photos of what this Replica E-crazyman controller looks like

photos of one of the replica e-crazyman controllers i have..

ON THE TOP LEFT OF THE FIRST PHOTO YOU WILL SEE THE RESISTOR THAT COULD BE CHANGED TO A LOWER VALUE (I USED 4.5kohm RESISTOR TO BRING MY SPEED TO 25KM/H WHEN I TESTED IT AT 66V ON MY 5304 24")

the board was coated in the jelly weather proofing .. i did my best to take it of

some more info on this controller could be found here on my older post
http://endless-sphere.com/forums/viewtopic.php?f=2&t=6608&p=100584#p100584

-steveo

 

[Microbatman]

Stevo

Nice work thanks for the test.

Nice work on the 4110's

One quesiton.

Asking cus I know you have had both Crystalyte and E-crazyman both.

How does the throttle resolution for the E-crazyman to the Crystalyte?

When you roll the throttle on and off is it as smooth?
Or is is more like just a few notches of power choices?

 

[steveo]

Stevo

Nice work thanks for the test.

Nice work on the 4110's

One quesiton.

Asking cus I know you have had both Crystalyte and E-crazyman both.

How does the throttle resolution for the E-crazyman to the Crystalyte?

When you roll the throttle on and off is it as smooth?
Or is is more like just a few notches of power choices?

If you where to use a crystalite controller or my (knockoff e-crazyman controller) you would not notice any difference.

I really like this controller because it has an adjustable LVC & adustable Speed-aperage governer (i think this limits the throttle is how it works)

i'm very please with the results this controller has given me today when i did my first test ride! .. I think i will be getting a set of 150v mosfets because i have so many spares of these controllers i can survive if i blow it anyways!!... and this time ... i will test with 133v with a light bulb in series so that the current doesn't rush to fast to the controller and blow like i did with one of my older 35amp x-lite controllers!!..

-steveo

 

[drunkencat129]

hold on to ur hats 200v or 220 coming soon lipo packs on e scooter steve i got more cells so we got to give me a hand on my crazy battery o and ps u can feel 80 v at 10ah threw ur forarm only lol its vary tiny but its not that bad lol so id say ur crotch is safe lol unless u add water lol

 

[philf]

Hey Steveo...

Just curious what that controller came with, or how it is was "branded". It's the same Shenzhen unit that Golden Motor ship with their kits - I've got a couple of spares of these, so you have me thinking about a few component upgrades. I confess that I've never had a problem with these controllers - and although all of the external logic to drive the FETS seems old school, I still have warm feelings for their hackability.

 

[Doctorbass]

One day.. we will really see newspapers articles with big titles like:

=== DEATH BY ELECTROCUTION ON HIS ELECTRIC BIKE ! === :x

Just using by 100V setup when i come from a ride on rainy day, i had electrical shock on some connector with rain on them..... sometime very high! :x

Pay attention guys! :wink:

Doc

 

[steveo]

Hey Steveo...

Just curious what that controller came with, or how it is was "branded". It's the same Shenzhen unit that Golden Motor ship with their kits - I've got a couple of spares of these, so you have me thinking about a few component upgrades. I confess that I've never had a problem with these controllers - and although all of the external logic to drive the FETS seems old school, I still have warm feelings for their hackability.

The stock factory controller has:

NF75NF MOSFETS
3 - 63v 470UF caps
32 amps shunt
Cutoff around voltage at 41v
Factory included speed/aperage governer

One day.. we will really see newspapers articles with big titles like:

=== DEATH BY ELECTROCUTION ON HIS ELECTRIC BIKE ! === :x

Just using by 100V setup when i come from a ride on rainy day, i had electrical shock on some connector with rain on them..... sometime very high! :x

Pay attention guys! :wink:

Doc

Wait till i get my 150v mosfets doc ..

sorry i havn't sent you the photos yet, for some reason i haven't been able to post on the form yesterday and this morning from my home computer .. I'm at my friends house using his pc; I've taken the photo's already I will send you tonight.

-steveo

 

[steveo]

.

 

[Doctorbass]

One day.. we will really see newspapers articles with big titles like:

=== DEATH BY ELECTROCUTION ON HIS ELECTRIC BIKE ! === :x

Just using by 100V setup when i come from a ride on rainy day, i had electrical shock on some connector with rain on them..... sometime very high! :x

Pay attention guys! :wink:

Doc

Wait till i get my 150v mosfets doc ..

sorry i havn't sent you the photos yet, for some reason i haven't been able to post on the form yesterday and this morning from my home computer .. I'm at my friends house using his pc; I've taken the photo's already I will send you tonight.

-steveo[/quote]


no prob!

 

[steveo]

Hey Everyone

Here are some photos of my successfully modded controller!

My Sweet ride

Video of my bike in action with the new controller & my neighbors ride!

http://www.youtube.com/watch?v=OY81RCD22sQ
http://www.youtube.com/watch?v=5q0pUn_kjQg

there is a 3rd video that is a 11 mins and dam youtube won't let me post ..

hope this is good enough for now

-steveo

 

[Doctorbass]

Hey Everyone

Here are some photos of my successfully modded controller!

Video of my bike in action with the new controller & my neighbors ride!

http://www.youtube.com/watch?v=OY81RCD22sQ
http://www.youtube.com/watch?v=5q0pUn_kjQg

there is a 3rd video that is a 11 mins and dam youtube won't let me post ..

hope this is good enough for now

-steveo

Nice! what speed did you recorded on the second video at 3:33?

With a 5305 at 100V on a 24" wheel i recorded max 76kph on flat.. so with a 5304.. that cold be more i guess!

You limited your mooded controller to how many amp max?.. or how many am did you measured?.. and does your C-A is calibrated with your mooded shunt?


Doc

 

[steveo]

Hey Everyone

Here are some photos of my successfully modded controller!

Video of my bike in action with the new controller & my neighbors ride!

http://www.youtube.com/watch?v=OY81RCD22sQ
http://www.youtube.com/watch?v=5q0pUn_kjQg

there is a 3rd video that is a 11 mins and dam youtube won't let me post ..

hope this is good enough for now

-steveo

Nice! what speed did you recorded on the second video at 3:33?

With a 5305 at 100V on a 24" wheel i recorded max 76kph on flat.. so with a 5304.. that cold be more i guess!

You limited your mooded controller to how many amp max?.. or how many am did you measured?.. and does your C-A is calibrated with your mooded shunt?


Doc

Hey doc

I never maxed out speed; I could tell you on my 26" 5404 at the time i did 80km/h; so on a 24" it probably very close to this but faster then you !!

well my shunt is not configured correctly on the c/a yet .. but its pertty close it displays 21-22 amps fully governed ... you will love the governer doc .. i can do 32km/h with 100v LOL..

The controller i will be sending you is pertty much dead on with shunt value i estimated with my watts up .. I the shunt in controller i will send you is .7666mohms ( i have my c/a in kw range not watts)

-steveo

 

[Doctorbass]

Oh!.. pretty fast 80km/h! for sure .. 3.3km/h faster than me ... now can you tow two car at the same time with it

Over the month, it turned out that my present ebike setup approached more and more a motocross setop.. more torque, very good handling, full suspensions and 8" diskbrake.. Now i thing i would really keep that way of the most powerfull torque ebike using hub motor...I think i could not do more than using a 5305 at 100V 100A on a 20" wheel! ...

So i'll keep this way for that setup.

On next summer maybe i'll plan to build a 5303 on a 26" rim at 150V at like 70A using a Kelly controller. I would really love breaking the 90km/h limit... à record STILL not reached on a crystalyte hub motor i think...

So i could have one VERY fast ebike... and one monstruous torque ebike

I'll see

Doc

 

[steveo]

Oh!.. pretty fast 80km/h! for sure .. 3.3km/h faster than me ... now can you tow two car at the same time with it

Over the month, it turned out that my present ebike setup approached more and more a motocross setop.. more torque, very good handling, full suspensions and 8" diskbrake.. Now i thing i would really keep that way of the most powerfull torque ebike using hub motor...I think i could not do more than using a 5305 at 100V 100A on a 20" wheel! ...

So i'll keep this way for that setup.

On next summer maybe i'll plan to build a 5303 on a 26" rim at 150V at like 70A using a Kelly controller. I would really love breaking the 90km/h limit... à record STILL not reached on a crystalyte hub motor i think...

So i could have one VERY fast ebike... and one monstruous torque ebike

I'll see

Doc

You are right its one thing after another to improve our builds, This is the fun of it all!!

Doc for 150v I suggest using a 5305 like you have. Why? well at higher wind resistance I prefer to have more torque to push my bike harder then a 5303 that may never reach its top rpm because it is wound higher. Just my 2cents


FYI EVERYONE

THIS IS WHAT I GOT TODAY FROM USPS; I LOVE USPS 1 week to ship to me!! $8 shipping SWEEETT

my fdp2532 mosfets 24 pieces!!!

Guess what i will be building this weekend!!

-steveo

 

[drunkencat129]

WOOT thay came in hehe i got the controller sitting on my shelf call me steve asap when u see thiss lets get thiss going lol also i want to run the 100v controller on my Electric scooter lets see what it takes to fry a 500w 48v ebike scooter brushless motor

 

[drunkencat129]

Oh!.. pretty fast 80km/h! for sure .. 3.3km/h faster than me ... now can you tow two car at the same time with it

Over the month, it turned out that my present ebike setup approached more and more a motocross setop.. more torque, very good handling, full suspensions and 8" diskbrake.. Now i thing i would really keep that way of the most powerfull torque ebike using hub motor...I think i could not do more than using a 5305 at 100V 100A on a 20" wheel! ...

So i'll keep this way for that setup.

On next summer maybe i'll plan to build a 5303 on a 26" rim at 150V at like 70A using a Kelly controller. I would really love breaking the 90km/h limit... à record STILL not reached on a crystalyte hub motor i think...

So i could have one VERY fast ebike... and one monstruous torque ebike

I'll see

Doc

i got a new e enduro coming in geared on a moped rim at 60v of limn it did 68 clean it had more speed in it but a ran out of road near my work also no problems with nice torq at 35a i can go up a steap hill with it it only slows down to like 20 km but the hill is extream also from a stop and go from the bottem of the hill it mantains a 10km speed up the hill suprizeingly from a dead stop lol needs a shunt mod

 

[steveo]

Hey Everyone

I hope today to be the only one to break the Voltage record for a crystalite at 133 nominal volts

photos of the test setup

videos will been post very soon

 

[Doctorbass]

OMG !!

Great work Steveo!

Now, I feel we are now 3 on the mark to make smoke coming out of a crystalyte hub motor Methods, You and me!

These motor should be renamed like "X10"... I mean 10 time their nominal power!

Please post vid AS SOON AS YOU FILMED YOU REACHING 80+km/h!

Doc

 

[steveo]

Videos as promised; no load test.

http://www.youtube.com/watch?v=L07t4TrkChI

http://www.youtube.com/watch?v=2r8bRab8Oho

THE GATE RESISTORS ARE NOT GIVING NO PROBLEMS AT HIGHER VOLTAGE !!

 

[fechter]

I don't see any posts from after the test.

Do you think it blew up and vaporized him?

Be real careful messing with those kind of voltages. Lethal for sure if you touch the wrong thing.

You can run most consumer electronics (anything with a switching power supply) right off you pack. You could also run most power tools. Just wire up a recepticle.

 

[steveo]

I don't see any posts from after the test.

Do you think it blew up and vaporized him?

Be real careful messing with those kind of voltages. Lethal for sure if you touch the wrong thing.

You can run most consumer electronics (anything with a switching power supply) right off you pack. You could also run most power tools. Just wire up a recepticle.

Ensure I am taking lots of caution handling this voltage.

lol .. who needs an inverter ..

-steveo

 

[Doctorbass]

The wheel is spinning crazy fast!!!.. It's like we just expect that the tire could get out of the rim!!!

Be carefull with these fets!.. they only are 79A and 16 mohm... Just quater of the 4110.. so I would recommand keeping the shunt current limit under like 40A


Oh.. and i forgot... did you said that the caps are 160V??.. If so, you must replace them for 200V.. the rules about these controller is usually

72V=100V cap
100V=160V caps
133V=.. probably 200V... and ... low esr..

And... how much voltage does the regulator see at it's input?... did you needed to replace the large flameproof kilohms resistor for a higher resistance to reduce the heat dissipation on it?

.. instead of the need of an inverter.. just try using that voltage on a vaccum cleaner.. with high dc they usually sound like a turbine.. or a tesla roadster motor

And.. thanks for sharing that!

Doc