will these rc electrics survive?

[bandaro]

Ok, hey guys, im new here, been into rc for several years now, and was referred to this site about building an ebike.

So basically i was wanting a lightweight high powered bike (not too powerful compared to some of the systems i have just seen) of about 3kw. i have asked all my rc go-to guys about it, and they think it should run fine, but have been told that no esc will handle the power of the system i want, with a single outrunner brushless and i should just go a commercial hub motor.

i was planning on using these as the electrics:

TGY AerodriveXp SK Series 63-74 170Kv / 3250W from hobbycity, linky: http://www.hobbycity.com/hobbycity/store/uh_viewItem.asp?idProduct=7870

For the esc i was considering either the sentilon 100A v4, k-force 120A or the turnigy monster 200A, cheaper is better but if the sentilon busts, it would have been cheaper to go the monster from the start, so what is the chances of blowing each esc?

Headway 3.2v 10ah (10c/15c) rigged as a 12s 1p pack for general use, and if i like them i will get a second set to rig in parallel. linky for the batts: http://www.e-mtb.com.au/headway-32v-10ah-cell-38120s-p-181.html

Will also run with a turnigy watt meter rigged to the handlebars. I am currently working on making a freewheel setup to have the motor powering the front sprockets, still having the full 21 gears, and be able to use the motor without pedaling, similar to some systems around here. I was going to rig the esc to be on the rear of the seat post, in the wind from the rear wheel, with a bigger heat sink fitted as space isn't too much of an issue. gearing will be aimed for 8km in lowest, and about 80 on top gear (whatever the top gear of the bike gives, but i worked it out at around 80 if the lowest is 8km/h at max rpm), but generally cruising around 30km/h, riding around town.

So, what do you guys with e-bike experience think of this setup, will it last? what is the best esc to use? are there any combo's that would be similar power and price that I don't know about? any major problems I may have overlooked? with a low kv motor like that will i have a big sync problem on low timing?

also, was looking for a current restriction of some type, to limit the amps to around 130 or so max. Any one got a link or can I get one off the shelf? (a watt limiter for around 3.5kw range would also work)

 

[gwhy!]

Hi And welcome to ES,

Very good choice of motor ... I am running one on my e-bike and am very pleased with it, My bike is only geared for around 25-28mph running on 44v of lipo I bought a hv100 turnigy esc when I first started playing around with the higher power setups ( the controller is still going but not used anymore ) I was not happy with the startup sync so I fitted hall sensors to my motor and now using a cheap sensored 6fet controller the whole thing works really well. If there is anything I can help you with please ask.

 

[MitchJi]

Hi,

what is the best esc to use? are there any combo's that would be similar power and price that I don't know about? any major problems I may have overlooked? with a low kv motor like that will i have a big sync problem on low timing?

Castle HV (HV160 for 130 amps) series are best for maintaining sync.

also, was looking for a current restriction of some type, to limit the amps to around 130 or so max. Any one got a link or can I get one off the shelf? (a watt limiter for around 3.5kw range would also work)

This will do it:
http://www.endless-sphere.com/forums/viewtopic.php?f=28&t=11682

 

[bandaro]

Hi,

Castle HV (HV160 for 130 amps) series are best for maintaining sync.

so you think i will have a problem with the sync? a small amount of cogging (second or two) i can deal with.

gwhy, does your motor get hot at all? what kind of amps does it draw, if you know? as for the sync, do you think the new v4 can control it better?

 

[gwhy!]

Hi,

Castle HV (HV160 for 130 amps) series are best for maintaining sync.

so you think i will have a problem with the sync? a small amount of cogging (second or two) i can deal with.

gwhy, does your motor get hot at all? what kind of amps does it draw, if you know? as for the sync, do you think the new v4 can control it better?

the motor do not get hot and I have pushed 5kw though it in bursts, the v4 is what I have yes it works ok but did stuggle from a dead stop ( you would need to get the bike moving slightly before winding up the throt ) I think this also applys to the CC esc.

 

[drewjet]

I still have the Turnigy 100 Amp ESC on my bike. I also have a Castle 110HV, but did want to risk blowing it, so I figured I would run the Turnigy for a while. So far it has worked awesome. I have ran 8000 watts through it in very short bursts with no issues at all. It does get warm when I am pushing it pretty hard on the off road trails, but cools off quickly once I am back on the streets. I have put a few hundred miles on it so far and am quite happy with it. I have no issues with starting from a dead stop, however I am running an Astro 3220 6 turn, not an outrunner.

Good luck with your build. Be sure to start a build thread with lots of pictures.

 

[drewjet]

Just remembered. Look into getting a Cycle Analyist. You need the power wires to be as short as possible. You can remove the shunt from the watt metter and remote mount it, but trust me having a CA is the way to go.

Also make sure you add extra Capacitors to the ESC, search for the thread on it

 

[bandaro]

Just remembered. Look into getting a Cycle Analyist. You need the power wires to be as short as possible. You can remove the shunt from the watt metter and remote mount it, but trust me having a CA is the way to go.

Also make sure you add extra Capacitors to the ESC, search for the thread on it

so the turnigy 100A has worked for a few years for you? sounds promising, but you do have a different motor... 8000 watts is good, my motor wont pump more than 6 ish on a burst, so if your turnigy handled 8kw bursts...

as for the cycle analyst, the turnigy watt meter measures more of the electrically related things, so i was leaning that way, i already have a bike computer thing so i am right as far as speed, distance etc go. watt meter can be mounted as an extension to the controller wires and the controller will be mounted within 10cm of the motor, if all goes well. batts will be as close as possible, but cant really alter that too much, as they are bigger so cant be stuck just anywhere.

as for mounting caps, im fine with that, what size would be recommended, biggest i can get or copy whats on the esc? i was thinking about adding caps before, just reduce the strain on the batts when i punch it. also, been looking on the site, but i cant find the number of poles on the motor?

 

[drewjet]

so the turnigy 100A has worked for a few years for you?

No it is only been a few hundred miles.

I don't know what the Wattmeter will give you that the CA doesn't. It has Amps, Watts, Volts, AH used, plus because the speedo is integrated it gives you WH/mile a good way to gauge your efficiency. I am not trying to sell a CA, but it has proven to me to be very useful and nice to have everything in one package.

 

[MitchJi]

Hi,

My bike is only geared for around 25-28mph running on 44v of lipo I bought a hv100 turnigy esc when I first started playing around with the higher power setups ( the controller is still going but not used anymore ) I was not happy with the startup sync so I fitted hall sensors to my motor and now using a cheap sensored 6fet controller the whole thing works really well.

the motor do not get hot and I have pushed 5kw though it in bursts

You are running ~115w through a "cheap sensored 6fet controller"?

Would you provide a little more information?

 

[gwhy!]

Hi,

My bike is only geared for around 25-28mph running on 44v of lipo I bought a hv100 turnigy esc when I first started playing around with the higher power setups ( the controller is still going but not used anymore ) I was not happy with the startup sync so I fitted hall sensors to my motor and now using a cheap sensored 6fet controller the whole thing works really well.

the motor do not get hot and I have pushed 5kw though it in bursts

You are running ~115w through a "cheap sensored 6fet controller"?

Would you provide a little more information?

the controller is a 6 fet keywin controller moddifed slightly with higher rated fets and better cooling than standard (approx £20.00 uk pound addition of the cost of the controller ) its currently limited to 70A max but will run this all day ( have ran it at 100A max for a little while ), the motor is a TGY AerodriveXp SK Series 63-74 170Kv / 3250W , the bike is a 26" hardtail trials bike fitted with front susspension , what more would you like to know .

 

[MitchJi]

Hi,

You are running ~115w through a "cheap sensored 6fet controller"?

Would you provide a little more information?

the controller is a 6 fet keywin controller moddifed slightly with higher rated fets and better cooling than standard (approx £20.00 uk pound addition of the cost of the controller ) its currently limited to 70A max but will run this all day ( have ran it at 100A max for a little while )…

what more would you like to know .

I wanted to know the source for sensored 6fet controller's that can handle 100a. It sounds like that would require modifying a controller which I don't think I'd tackle.

Thanks!

Mitch

 

[Thud]

Here Ya go MitchJi:
http://endless-sphere.com/forums/viewtopic.php?f=31&t=18744

(it feels good to post an info link in your thread...you allways beat me to them! :lol: )
Talk to Lyen about his programing of the unit's. I am certain he will flash your requests onto the controller prior to shipping. (should you decide to attemp these)
Then again programing is very easy to do & fun to tinker with....Just include a programing cable & let the good times roll.

 

[gwhy!]

Hi,



I wanted to know the source for sensored 6fet controller's that can handle 100a. It sounds like that would require modifying a controller which I don't think I'd tackle.

Thanks!

Mitch

Sorry Mitch I wasnt to sure what you were asking, Yes the controller has been modified. Its really not to bad to do yourself, but as thud has posted the lynen controller looks like a safe bet if you do not fancy modding one your self from scratch.

 

[MitchJi]

Hi,

Thanks gwhy and Todd!

Here Ya go MitchJi:
http://endless-sphere.com/forums/viewtopic.php?f=31&t=18744

(it feels good to post an info link in your thread...you allways beat me to them! :lol: )
Talk to Lyen about his programing of the unit's. I am certain he will flash your requests onto the controller prior to shipping. (should you decide to attempt these)
Then again programing is very easy to do & fun to tinker with....Just include a programing cable & let the good times roll.

The email's from the threads I'm subscribed to are filtered into a dedicated email mailbox which is easy to search.

Thanks but its not the programming I'm mainly concerned with. It's beefing up the traces, upgrading FET's etc.

I copied some of these posts to the following thread:

Castle HV160 Controller vs Sensored (Hall vs Optical)

http://www.endless-sphere.com/forums/viewtopic.php?f=28&t=18792&start=0

as for mounting caps, im fine with that, what size would be recommended, biggest i can get or copy whats on the esc?

http://endless-sphere.com/forums/viewtopic.php?f=28&t=7504


Thanks Again !

Mitch