Phoenix ESC Test Run 2
I put the Phoenix HV-110 ESC in the same aluminium project box that houses my low-voltage electronics. I mounted a temperature controlled CPU fan on it and ran the fan off the 12V line on the low-voltage converter.
The fan was in a "blow" configuration but I think I will change it to a "suck" config as I think that is more efficient for this type of fan.
The servo tester is mounted on my handlebars. Once my Magura throttle comes in (backordered), I'll be able to use that as a regular motorcycle throttle. The switch on the dashboard is for the lights. I have two high-power LEDs mounted in the headlights. The new white LEDs are so efficient that I can use a 5V 1 watt bulb instead of the old 6 volt 10 watt incandescent.
Everything was mounted on with duct tape and the batteries put in a small canvas bag that I had and I was ready for test drive #2 with the Phoenix HV-110 and HXT outrunner motor.
Notes on the test run:
- I was very surprised that my lights and the CPU fan cut out on full throttle! Coming back home, I later realized that the DC-DC converter at the heart of my low-voltage system is rated 36-75V. I'm running the bike on a 38.4V NiMH system, but at full throttle I have enough voltage sag that the power module cuts out. I'm ordering a new 15-40V --> 12VDC power converter from Digikey and that should solve that problem. Redoing my low-voltage module is a pain.
- Argh. If I was able to use 48V with the Phoenix ESC than I could've gotten away with the current 36-75 volt DC-DC converter. Double phoeey.
- With 38.4 VDC 3.8 Ah, I was able to go approximately 3km (2 miles) at 20 kph (15 mph). I think I'll get 3 more of these packs, which would give me a total range of 12 km (8 miles).
- Dang my NiMHs were hot coming off the test ride. I really need more packs in parallel to take some of the stress off the single large pack that I'm using. Still no good charging solution, I'll most probably just have to use a bank of 19.2V chargers.
- The ESC was not warm at all, so it looks like the fan is working well. The aluminium enclosure also helps with heat dissipation.
- There was a rattle in my belt-drive system that I narrowed down to a slip caused by the difference between the 1/2" pulley and the 12 mm spindle. Half an inch is 12.5 mm, so there is a 0.5 mm gap that is rattling. I think I'll shim it with some copper shim material I have lying around.
I'd love comments!