48V+ Controller and LCD recommendations

HaTaX

100 µW
Joined
Mar 25, 2021
Messages
7
I've got a Freego scooter that the controller finally gave up the ghost, one of the STP75NF75 fets went bad and I think I may have wrecked the trace on it when removing it. The stock controller had a few nice things that I can do without; automatic headlamp and 2 switched outputs. One output was the headlight which was automatically controlled as well, and the other goes to the RGB strip lights on the sides. These were switchable by holding the up or down arrow on the LCD.

That aside it was running right at the controller's limit of 20A @ 48V which put about 960 watts to the motor. I could ride it for an hour easily and the motor never got very warm so I feel confident it can take some additional power. Looking on eBay, Amazon, and some other sites I'm having trouble locating a controller that looks like it'd be a good fit. Ideally the controller would also be able to handle 60 or 72V as well so I could change out the battery in the future and go with a higher voltage pack configuration if I wanted to. I also noticed a bunch of the controllers that look like they'd work on eBay don't have any dimensions listed, that's a problem as I've got limited space to try to work within...

What I'm looking for spec wise:
1000 watts or better
48/60/72V capability
25+ Amps (Higher obviously better, less stress on the controller when staying well under the rating)
LCD connectivity for speed, odo, etc. (Ideally included or paired with controller)
Max Dimensions: 160mm length, 83mm width, 65mm height (length could be a little longer but I'd like to keep room for wires)
Bonus feature: Programmable / adjustable either via PC or LCD

Any ideas on a decent controller I could shove in there to meet my needs?

I really like this controller but I don't think it will take a LCD screen:
https://www.uumotor.com/ws/p/sine-wave-foc-programmable-24-48v-30a-bldc-controller/
 
I would recommend looking into the KT series of controllers, which come in several sizes, and are customizable to some degree via LCD displays. Or you can customize them even more using the Open Source firmware:
https://endless-sphere.com/forums/viewtopic.php?t=87870
https://opensourceebikefirmware.bitbucket.io/
https://github.com/stancecoke/BMSBattery_S_controllers_firmware
https://www.google.com/search?q=kt+open+source+firmware

There are also certain LiShui (LS) controllers that also have OSFW available, but I don't know if they come in high enough power units for what you want.
https://endless-sphere.com/forums/viewtopic.php?t=106862
 
Thanks for the info! I wasn't aware of which controllers had open source firmware available for them so that's really helpful. I wanted to get an order in that I'd receive quickly so I actually ordered this one up from Amazon yesterday:

https://www.amazon.com/Kunray-Brushless-Controller-Dual-Mode-Electric/dp/B09SWTVSNJ

It's not perfect and I wish it was a little beefier but it's a mild upgrade from what's in there with connectors that will be almost completely plug and play for me. The smaller version of the controller even has the same LCD that's currently on the scooter, but it's been flakey so replacing it will be nice. One thing I'm curious about is the use of 9 FETs in this controller, since the length is only a little longer then the current controller I'm hoping they're spaced out a little better on both sides of the PCB which will help with cooling.

Once it shows up I plan to crack it open and have a peek at the internals provided there's no warranty stickers that will be broken. I'm also curious what kind of FETs are in use, with any luck it will be the IRFB3077s or better and not the STP75NF75s that were in mine and ultimately failed going up a hill.

Truthfully my old controller moved me along at nearly 30MPH and I was quite happy with that speed, so if it even matches it with a little more acceleration off the line I'll be a happy camper. I love to tinker, but it looks like I could spend a LOT of time with one of the programmable models tinkering. That's good and bad. :D
 
The Kunray controller showed up today and I took a look inside it, however they've got the FETs held to the heat spreader with a pressure clip / bar that would have been a royal pain to remove and pull it out. It is a 9 FET controller and for this particular scooter it was nearly 100% plug and play, even the old LCD was compatible with the new controller.

I did notice the old throttle that was part of the LCD didn't seem to have full travel as it wouldn't spin the motor over at its top speed, the pitch from the motor was noticeably higher using the new throttle with no weight on the motor. Otherwise the motor phase wires, hall sensor, battery (XT60), LCD, and brake connections all were the same connectors and it worked as soon as I hooked it up. Size is extremely similar too, just a hair longer (10mm) but not as wide or tall. Plenty of room left in the deck, and I might even be able to do a slightly larger battery as the LCD supports up to 60V it looks like. (I'd consider doing a 52V pack if I replace it instead of the current 48V)

Only thing I've noticed is the headlight, tail, brake, and RGB lights don't seem to be able to be powered off the headlight headers, most likely they don't support enough current through them. Thinking I'll solve that problem with a XT60 power tap and a small relay. Pretty sure I'll have to do something similar with the brake light to get it working as it has no brake light header off of it.

Performance wise, wow does it have a lot more torque then the old controller! No problem powering up hills that put the old controller into an odd low speed growling noise all the time. It really breathed new life into the scooter and I'm really happy with the modest boost in performance overall.
 
Back
Top