80 - 100 amp 3-phase brushless controller
I have a 1500 watt BMC 48 volt 3-phase brushless motor which I have had for about a year and a half. I couldn't be happier with the motor, but I'm cooking controllers out here in the deserts of Arizona. I have had the brushless controllers (4) which are rated stock at 55 amps modified to 70,80,90 and 100 amps, with varied degrees of success. However, the heat thats being generated is turning my controllers into solder meltdowns. I have added fans, which have helped, but I need to know who makes a 3-phase brushless controller that would match up to the motor I have. Incidentally, I purchased the Motor from Powerpack motors. Thanks for your input.
try kelly controllers,
their largest one will do 200A for a mintue, 100A continuous.
they do smaller ones aswell, but by the sounds of things, u need something beefy.
Maybe you could try putting 4110 mosfets in? Just a thought.
Can you tell us more about what exactly is melting (where on the board). Better yet, can you post photos of the blown controller boards?
You mention power mods to these boards - what exactly did you upgrade?
What is the ambient temperature these are failing in? What kind of load - weight and inclines?
Sorry to hear you lost your controllers.
I haven't used the Kelly controller but was looking at them myself. Would love to hear about your experience if you buy one. I'll do the same if I get to it first. I am modding a spare controller myself at the moment, will let you know how well it works.
A friend of mine is running the Kelly 150 amp one with the same motor you have. he had some trouble figuring out all the phase wires, but it runs great now and the controller doesn't get hot at all. Its nice that you can hook that controller up to a PC and change a lot of parameters to customize the way it works.
The smaller mosfets burned at built up solder along the circuit board 3 times and one of the mosfets actually cracked in two. The solder was built up to increase the amperage up from the 55 amp so that they were ranging from 55-100 amps.The ambient temperature was varied. The average would have been around 90 degrees. Only one of them cooked when I was going flat out in about 110 degrees trying to catch someone in a car. The rest of them seemed to really get hot when I was putting around in very small hills and in grass. My gearing was a little tall, but the motor had fairly quick acceleration off the line. I' am 180 lbs, but I don't know what the scotter weighted, but the last controller had 4 ah 22's to push around on stock tires. I had photos but computer crashed and I lost photos.
So, if I'm hearing this right, you beefed up the power traces, but not the MOSFETs? If that's the case, replace them with something beefy. 4110s are pretty much the best you can get.
Bob McCree, huh? He's got an account here. He's over on Endless-Sphere, too. I'd PM him to see what the deal was.
EV blingage: The best kind of bling. ;)
I could have sworn there was another step to that 60,000 electric RPM thing. Something involving a six...eh, can't remember.
The problem with the motor going to fast is the MCU isn't able to keep up, and makes the signal to the FET gate drivers get all wonky. If it's really bad, then you could even end up getting shoot-through (two phases being on at the same time), which will kill the FETs pretty much instantly. I'd be careful, if I were you...
That looks like a Stealth. I would love a 1500w Brushless motor for my Stealth.
Probably. If you wanna try it, there might be a visible clock oscillator for the CPU. Replacing it with a faster resonator would overclock the CPU and give you a higher RPM limit. Works for the e-crazyman controllers, anyway.
See sig. ;)