replacement controller for Kasea ZE2000

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Jayman
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replacement controller for Kasea ZE2000

I understand the design of the Kasea ZE2000 is the same as the E-Max. My controller lost a part while hitting some rough terrain. Is there a better controller I can bolt on? If not, where can I get a replacement? I am kind of hoping for a better controller I can buy. This is my first EV and is sort of a knowledge gathering mission. So far, I gather that Chinese production methods do not produce great quality. Some epoxy on the inside of this unit would have gone a long way.

PJD
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Re: replacement controller for Kasea ZE2000

Another 3-phase brushless controller might be adaptable to you scooter but finding one and adapting it will be be a lot of work. I am keeping an eye out for a spare Kasea/E-max controller myself. They should be around - they are used in a number of Chinese scooters. Google around - maybe here: http://www.neoscooters.com/street-legal-electric-scooters.asp

Vinnie Basile may have more information. Vinnie, can you help us out?

By "lost a part" do you mean that a filter capacitor shook off the circuit board? With a little luck, no other damage to components was done and the capacitors can be replaced, securing the new ones with silicone so they don't shake loose again. The only damage mine had was some melted control wires when the remaining intact capacitor overheated, this disabled the controller before kept anything else got damaged.

If something else was was damaged, it was likely one or more of the power MOSFETS. These can be replaced too. PM me for more info.

Jayman
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Re: replacement controller for Kasea ZE2000

Thanks for your post. I am holding this part in my hand...(I am no electrical engineer, by any means) E13005-2 is what is inscribed in it. 1/2 in square black plastic box attached to a piece of metal with a hole drilled in it that extends 3/8" above the black box. Two of The three prong legs were broken off of the board with 1 remaining in it(if I am correctly determining the location that it used to have on the board). The black plastic also seems to have been cracked near the prongs. I fear this part is no longer serviceable. I will attempt to contact Vinne as well. Thank you.

PJD
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Re: replacement controller for Kasea ZE2000

The part you described is an NPN transistor. Was it located between a large filter capacitor (can with black plastic wrap) and a small transformer (square thing)

Any burnt smell?

It should be easy to replace. Find someone who can do electronics repair or send me a PM and I can probably do it.

vinnie
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Re: replacement controller for Kasea ZE2000

Jayman,

My thoughts: if you can get the controller repaired, go that route while you search for a controller upgrade. If no one is local for you, take Paul (PJD) up on his offer. Replacement controllers are getting harder to come by.

Some options for a replacement controller are:
1) Contact E-Moto in Seattle. I bought a replacement controller from them when mine blew up, although they haven't responded to any of my recent emails.
2) Try Kasea to see if they still have any spare controllers laying around.
3) Contact GreenEMotors in California. They claim to offer support for E-Max owners. Check out there statement on the matter. I contacted them in the past with pleasant results but never asked them about a controller. Worth a try.
4) Mountain Chen, a distributor in China and a member of this forum, has offered to replace controller/motor setups on our e-max's for $400, I believe. I don't know anyone who has done this yet so it is unclear if there will be compatibility issues. My scoot has 12" wheels so I am looking to see if Mountain's 13" setup would fit. If so, I may eventually take him up on it. I would PM (our on-site email) him and see what he can do for you if you can't get the repair.

Any questions I can answer or assistant to offer, don't hesitate to send me a PM (just click on my name and look for a link to do it).

Cheers!

Vinnie
Broomfield, CO

ratatouille
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Re: replacement controller for Kasea ZE2000

Hi Jayman,

I don't know if he still has the controller left but Joe from Segway was selling his Emax Sport for parts.
I bought the motor from him, very nice transaction.

You can find him at the end of this post.

I tried a Kelly KEB controller with it and it worked fine.

Jean-François

PJD
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Re: replacement controller for Kasea ZE2000

Jean-François wrote:

I tried a Kelly KEB controller with it and it worked fine.

Good tip! I just might buy one. The right products seem to be finally coming out.

Did you get a regen version?

Did you have any problems getting the motor phase and hall sensor wires connected to the right terminals?

Thanks,

Paul D.

vinnie
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Re: replacement controller for Kasea ZE2000

Woa!!!

Also, if the Kelly KEB worked, does this mean we can go to 72v???

Think the motor will handle it?

Vinnie
Broomfield, CO

ratatouille
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Re: replacement controller for Kasea ZE2000

Hi,

so no regen for my KEB72450.
The only "problem" is to find the right combination for the phase and hall wires but with a little patience, it's ok.

The correct wiring with the Kelly is :
A=Blue - B=Yellow - C=Green

On the road, it is very silent and acceleration is smooth and powerfull. Of course it depends on the maximum armature current you set. With 35% (about 45A max battery side), it's already nice.

In the following video, the testing at home, battery voltage 53.5V, rotating speed 64km/h (on flat road >=50km/h) :

For 72V setting, the Kelly can do it, i think the motor may be but what about the brakes ?

Jean-François

PJD
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Re: replacement controller for Kasea ZE2000

Jean-François,

Thanks for the information.

What tire size (wheel dia.) was used for the 64 kmh rotating speed? My e-max on level road, 50 volts or so, would achieve 58-60 kph on level ground and 3.50 x 10 tires. If you have the information in RPM it would be appreciated.

ratatouille
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Re: replacement controller for Kasea ZE2000

The bike speedo was set with a wheel diameter of 1307mm.
The tire is 3.00x10.
I'm talking about real speed, GPS measurement, not the speedo of the scooter which is at least 10% wrong.

It also was hard for my small battery to support the 45A and the wiring was not optimized (diameter and too much connectors) so the voltage drop was quite high (so max speed lower).

I should add another battery for better result.

Jean-François

vinnie
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Re: replacement controller for Kasea ZE2000

Alright peeps,

Looks like I will be in the market for another controller...again. Does this Kelly controller need to be programmed by the end user or is this thing plug-and-play?

Cheers!

Vinnie
Broomfield, CO

reikiman
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Re: replacement controller for Kasea ZE2000

Does this Kelly controller need to be programmed by the end user or is this thing plug-and-play?

Yes. You can do both, or either, whatever you wish.

- David Herron, The Long Tail Pipe, davidherron.com, 7gen.com, What is Reiki
- Electrified Electra To

vinnie
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Re: replacement controller for Kasea ZE2000

Sounds nice! I'm going to start saving up...

I found some screenshots of Kelly's "Programming Wizard". Seems easy enough...with a little help from my V friends, no?

Vinnie
Broomfield, CO

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