The 150V Upgrade

[knoxie]

Hello

Well the 150V controller has been running well, runs cool and I have pushed it up to 48V now and its working fine, will take things slowly and see how it looks, I am hopeful it will be good for at least 100V now, here are a few snaps of the mod.

Cost about 40 dollars to modify it to 100V and took about 7 hours in total, this would come down a lot with more practice and with a known good controller that hadn't blown, still its got to help, those pesky plastic tubes will eventually perish on all these controllers given time and temperature, I am going to replace them washers on all my other controllers as this is relatively quick and easy to do, I have 3 other controllers to do

Cheers

Knoxie

 

[knightmb]

So now you can have a (quick math) 5,250 watt e-bike!!??!

Where to put all the batteries?!??

 

[29a]

T33W5

youthank

 

[knoxie]

Hi

Well I kept the limit on the busbar to 35A as you are right I havent got the batteries for anything fatter than that for now, it should in theory be capable of 45A at 100V with the an extra bar! sounds like an electric fire now doesnt it! ha ha.

Ramping up nice and slow with it now need to make sure its reliable in general and also need to beef up the support on the torque arm before I run 72V.

Cheers

Knoxie

 

[xyster]

Nice work

 

[knoxie]

Cheers Xyster

Yes I hope so, I never rush anything hope its going to pay off, it seems to be a luck of the drawer thing at higher voltages with these controller, you seem to have a good one which is good news, I have seen so many bad ones I can still smell the burned silicon :lol:

I have a new BMS to sew in to a lipo pack now so I can have a play at higher voltages right up to and over 100V If I want to, will need to watch where I leave my spanners!! ha ha

Cheers

P

 

[Ypedal]

Awsome !!!

Thanks Knox !!! 8)

To remove the old fets, do you use de-soldering braid or a suck-pump type thing ? or simply heat the legs and pull the fet ?

 

[CGameProgrammer]

To remove the old fets, do you use de-soldering braid or a suck-pump type thing ? or simply heat the legs and pull the fet ?

You do NOT pull the FET while solder remains, because that can pull at and remove the traces from the circuit board, from what I understand. You remove the solder (using either of those two methods, whatever works) and only remove the FET when you know it's no longer attached.

 

[knoxie]

Hi

Yes I use a decent quality de-soldering pump and get away most of the solder around the leg and then hold the remaining piece of leg then using a pair of flush cutters and then using the iron applying heat to the tip of the exposed leg to gently ease it out.

I snip the fets out first, unless you intend to keep the old fets it makes the job a lot easier, I didn't lift a single track doing this mod, it takes time but so does repairing tracks!

Good luck

Knoxie

 

[Stevil_Knevil]

Stunning work, Knoxie! Really.. top-shelf gear.

If you keep this up, I'm going to be forced to take apart a perfectly good controller to do this high-voltage modification.

Two questions:

- What is the supplier and part # for the FETs that you are using?
- which of your bikes/motors is going to see the full 100V brunt of this little beastie?

Best of luck @ 72V,


-S

 

[knoxie]

Hello Mate

Thanks for the compliments, there has been a lot of smoke on the way but it has been fun so far! ha ha, yes the fets I used are 150V 80A, part number FDP2532-ND, I got them from Digikey in the states and had them shipped over, we don't seem to sell exotic stuff like that over here in the UK.

It was funny when I ordered it I had to fill out a lengthy online form detailing what the parts were intended for and everything! ha ha Is suppose its a sign of the times.

The 26 Inch Puma bike will see the force again, it failed once but that was the controller not the motor as the motor is still fine, I will surely let you know if it rocks at 100V, I see no reason to believe now that it wont will all the mods in place and the testing all done properly.

I should think there is a little market for upgrading the controllers, only something to be done if you haven't got a girlfriend and like sleeping!! ha ha.

Nice to hear from you Steve.

Paul

 

[CGameProgrammer]

It was funny when I ordered it I had to fill out a lengthy online form detailing what the parts were intended for and everything! ha ha Is suppose its a sign of the times.

That doesn't happen when shipping within the U.S.

 

[knoxie]

well one could argue it should do I suppose, the enemy within and all that. It was the first time ever that I have had to do this! but hey got nothing to hide have I? did seem strange asking all these questions, when there are far more dangerous things you can buy without any background checks at all?

Knoxie

 

[CGameProgrammer]

Remember the PR campaign for the Aqua Teen Hunger Force movie, in which LED signs of a cartoon character giving the finger were placed in various places among 15 cities? Boston actually thought it was a terrorist plot because some people saw exposed electronics and though anything electronic must be a bomb.