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  1. S

    24 Mosfet Controller XJC8b116 microchip Information Thread

    The 116 is a custom chip made for Xie-Chang. https://endless-sphere.com/forums/viewtopic.php?f=2&t=12416 All of the Xie-Chang 116 based controllers are similar, except the number of paralleled FETs and the input power supply. There is a schematic here...
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    New 'Mini Monster' Programmable Controllers Coming

    The maximum voltage drop the LM317 can handle is 40V. I think the minimum current is about 50mA. We want 12V output, so that leaves 48V to drop across the power resistor if the maximum battery voltage is 100V. That would require a 960 ohm resistor. I think I ended up using 1K. I'm changing...
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    Methods 100V 100A Programmable Regen Controller

    There is some information on the newer setting of the "Keywin E-bike Lab" in this thread (second post): https://endless-sphere.com/forums/viewtopic.php?f=2&t=12255
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    has anyone bought the "a123"a from ebay?

    I purchased some cells from this seller: http://cgi.ebay.com/4PCS-New-A123-2300mah-Li-Ion-26650-Lifepo4-Battery-Cell_W0QQitemZ190338256711QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item2c510b4f47 They appear to be seconds, but the only problem was they were double wrapped with the green...
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    New 'Mini Monster' Programmable Controllers Coming

    With this voltage it should be 1K, but I didn't have one, so I'm using 1.2K. I also changed R11 to 19.6K. The shunt is .001 ohm.
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    New 'Mini Monster' Programmable Controllers Coming

    I went for a 5 mile ride. All flat ground. I thought I had solved the throttle cutting out problem, but it is still there. Other than that, there were no problems. The controller, motor, and battery stayed cool to the touch (I wasn't monitoring the temperature). Voltage was just over 100V...
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    New 'Mini Monster' Programmable Controllers Coming

    I finally have a new battery put together. This is a 24s, 5ah, 20C made from four Turnigy 6s packs. It's just over 100V hot off the charger. I did a no load test with a Crystalyte 5304 motor. I need to get it all put back together and mounted on the bike, then I can take it for a spin :D
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    New 'Mini Monster' Programmable Controllers Coming

    The 0.5mOhm shunt should be alright. I think the original shunt was about 5mOhms, so you could scale the settings in the Parameter Designer by a factor of 10. I'm using a 1mOhm shunt I got from methods.
  9. S

    New 'Mini Monster' Programmable Controllers Coming

    I solved the problem with the controller cutting out by changing the input capacitor (C1) from 470uF to 1000uF. The 1000uF cap is about the same diameter, but longer. It just fits inside the controller. I wanted to see how hot the FETs would get under a constant load, so I chose a path up...
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    New 'Mini Monster' Programmable Controllers Coming

    I made the battery from two Bosch Fatpacks (Konion). It is 20s2p 18650 cells and I charge it to 83V.
  11. S

    New 'Mini Monster' Programmable Controllers Coming

    The CA doesn't keep max voltage AFAIK. The battery was still fresh since I wasn't very far into the ride. In order to get 10A flowing back to the battery, the voltage must have been very high. What I did different on this ride from the last one, is I was crouched down to keep the speed up...
  12. S

    New 'Mini Monster' Programmable Controllers Coming

    All repaired and back in operation. Let me see what I can break next :twisted:
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    New 'Mini Monster' Programmable Controllers Coming

    I didn't have a 620 ohm resistor, so I use a 680 ohm. I also cemented a thermocouple to the phase B high side FET. It's hard to see it in this picture, but the tip of the thermocouple is between the nylon washer and the plastic body of the FET, touching the metal tab. I went out for a ride on...
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    New 'Mini Monster' Programmable Controllers Coming

    Thanks dnum, I will try that. The 30mA I measured was with the controller not connected to anything else.
  15. S

    Simple current LED indicator for charger

    Maybe you could use a car ammeter from your favorite auto parts store, or junk yard. Here is another option: http://cgi.ebay.com/3-1-2-Blue-LCD-Digital-AMP-Panel-Meter-DC-50A-Shunt_W0QQitemZ250494265157QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item3a529f2745&_trksid=p4634.c0.m14.l1262
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    New 'Mini Monster' Programmable Controllers Coming

    There was some error in my calculations there. That was a ~19% increase, so the 75V regen setting would get a ~90V limit and the LVC should be set to 50.5 to get 60. (Thanks Ben!)
  17. S

    New 'Mini Monster' Programmable Controllers Coming

    I tried removing the CA, it didn't change anything. That last ride was with a stand alone CA, so it couldn't do anything to the controller anyway. The settings in the software are already maxed out. The reason I think it is the 5V dropping out is because I have to release the throttle to get...
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    New 'Mini Monster' Programmable Controllers Coming

    I went with a 1.2K resistor for R1. I measured 47V on the input to the LM317 with the battery fresh off the charger. Here is the result of the no-load test on a X5304 motor. The top CA is plugged in to the controller. The bottom one is stand alone and is set up to display RPM (multiply by...
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    New 'Mini Monster' Programmable Controllers Coming

    I finished wiring the rest of my controller. I'm going to be testing with two Bosch Fatpacks wired in series. That's 83V hot off the charger and 60V when it is drained (LVC). The "any voltage" transistor mod will be needed to cover that voltage range. There isn't much room to put it in...
  20. S

    Help, new 116 programer pinout.

    You can thank methods. He resolved this anomaly a few months ago in this post: https://endless-sphere.com/forums/viewtopic.php?f=2&t=10312&start=315#p169636
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    New 'Mini Monster' Programmable Controllers Coming

    I think that is all you need to do. There is a voltage divider made up of R10, R11, and R12 feeding a analog input pin on the MCU. I just noticed I omitted the values of R10 and R11 on the schematic. They are 10K and 7.5K ohms respectively on my board. This voltage is used for the low...
  22. S

    Instant Start 18 fet Infineon Boards are here...

    I posted a schematic (plan) in the 'Mini Monster' thread for the 6 fet controller. The schematic for this 18 fet controller is the same, except for the parallel fets and the 12V power supply section. Even the fet driver circuit is the same. The 12V power supply is already well documented in...
  23. S

    Help, new 116 programer pinout.

    If you want that setup to work, you need to put the switch in the GND wire instead of the +5V wire.
  24. S

    New 'Mini Monster' Programmable Controllers Coming

    I've made a schematic of this 6 FET Xie-Chang board. Except for the power supply section, the circuit is common to the whole family of controllers. That included the Infineon and 116 based 6 to 18 FET versions. If it has this symbol on it, it is from Xie_Chang.
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    New 'Mini Monster' Programmable Controllers Coming

    As Ben mentioned, I am building one of these little monsters and will be testing it's limits. I just started building yesterday. Here are some pictures of the power section. The holes in the board are too small for 10 gauge wire, so I crimped 45A Anderson Powerpole terminals to the wire and...
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