hi all,
i'm modding my 400w koll for a project...had no problem rewiring for CWR on a previous project, but now am running into a problem finding a 48v controller for the motor i am gutting. noticed a chinese dealer on ebay selling 600w brushless controllers fairly reasonably priced (except for shipping) but would like something with closer to 40A max. i guess my question is whether my assumption that i need a BRUSHLESS controller for this motor is correct (judging by the 3 phase wires vs. 2 on other brushed motors i have). am also wondering if a brushless controller is necessary, does that mean it will require a 5k pot vs. a hall-effect throttle? really don't want to spend $100+ on a controller...if need be will go with one on ebay. any help would be appreciated. i will be sure to post pics of my bike when done--a Swiss Army replica, 48v w/ 3 speed transmission. thanks.
Hate to break it to ya, but brushless controllers are kind of pricey, especially at over 20A or so. Those ones from e-crazyman on eBay are about as cheap as it gets. Even modifying one will run you close to $100, due to the number of replacement FETs and capacitors.
Whether you need a pot or hall throttle depends on the model of controller. Most controllers of the size used in ebikes and scooters are hall.
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You are going to be hard pressed to find any 48 Volt Brushless controller for under $100 anywhere, especially at 40amps (and yes that motor requires a brushless controller). I have been searching for brushless controllers myself and here is what I found.
First is the POWERPACK MOTORS 24-48v BLDC Motor Controller for $169.95
http://www.powerpackmotors.com./Powerpack-enhanced-shipping_included.html
I don't know what the amp rating is but you can email them and ask (powerpackmotors [at] socal.rr.com)
Another option is this controller used for e-bikes (36V 35A Start Immediate Controller, can be used up to 48V) for $170.00 but it's only 35amp
http://www.ebikes.ca/store/#BatteryAcc
If you really want high amps for a brushless controller you are going to have to pay a little more for the Kelly controller. You would want to get model KBL48101 it is rated for 48 volts and 60amps continuous cost is $229.00
http://www.kellycontroller.com/mot/Brushless-DC-Motor-Controller.html
The only other option that I know of (for 48 volt brushless) is the very expensive Millipak PMAC 36-48 Volt 200 Amp AC controller with regen for Brushless Etek for $480
http://www.electricmotorsport.com/PARTS/parts.htm
Hope that this helps.