How hot does the controller get?

[DavieH]

Hi I am fitting an electric bike kit to my wifes bike I want to fit the controller into a water proof box.
Can any one tell me how hot the controller gets I am a bit worried in case it gets too hot.
Thanks Davie

 

[Scottyf]

Most controllers I've had hardly get warm at all.

What controller are you using?
Most standard kits will be fine even if there enclosed.

I ran a 9 fet in a backpack enclosed and it was fine for over 6-8 months. Still worked when I sold it no problems.

I use a 6 fet now and have pushed 2500w from it and it does get warm. You can always hold it so it cant be much warmer on the casing than 40 degrees.

The general idea though is to keep it ventilated to get some air around it.
There are mosfets that screw onto the outer casing that use the case as a heat sink.

The more heat the less effcient electric is to a degree. So keeping it cool is best.

 

[DavieH]

Its a front wheel kit 250w with the battery pack that clamps onto the seat post. But I am having to fit it onto a rear rack thats why I have to move the controller from the battery pack.
Davie

 

[flecc]

Running cool is best, but despite that, many commercial e-bikes have fully enclosed controllers. For example, the eZee controller on their bikes is in a plastic box mounted on the rear of the plastic battery mount, so there's no heat sinking and very little air flow. Despite that it peaks at over 27 amps delivery. It's the black box just behind the battery in this photo.

 

[NRG]

Worst case a typical 15amp 6FET controller may produce approx 50w of heat at full output but in normal use the average will be far less...

 

[shemozzle999]

Would I be right in assuming it is a "frog" type battery and you can not get the saddle low enough for your wife.



If it is, I suggest the you remove the split plastic lower cover and the seat post clamp and have a sheet metal box formed which can be bolted to the existing 4 fixing screws located on the side of the battery slide plate and then the base of the box could be fabricated to bolt to the rack.
The removed plastic cover could be used as a template to make the metal one.
You would maintain the advantages of the existing system, but rack mounted ie: no wiring modifications, easy battery locking and removal and a secure location for the controller.

If you retain the old parts, it could then be returned to its original condition at a later date, if required.

 

[DavieH]

Hi thats more or less what I have done I wanted to make the controller and the connections water proof.
And your right it was not a good fit on the seat post and also the seat was to high.
Davie

 

[morphix]

Hi I am fitting an electric bike kit to my wifes bike I want to fit the controller into a water proof box.
Can any one tell me how hot the controller gets I am a bit worried in case it gets too hot.
Thanks Davie

Mine gets quite warm, but not laptop hot.. certainly not uncomfortable to handle and quite safe in a plastic enclosure.

 

[shemozzle999]

Hi thats more or less what I have done I wanted to make the controller and the connections water proof.
And your right it was not a good fit on the seat post and also the seat was to high.
Davie

I've had mine for 2 years now without any problems and I am in the process of replacing the motor wiring and making a few modifications at the controller end too. I loosely wrapped the controller in bubble wrap as it was rattling around when I first got the bike.
It is in excellent condition and so are the connectors considering the compartment is not completely sealed.
The large battery pack is quite good at shielding the compartment from above so I would not worry too much.
I would just make sure there are plenty or well positioned drain holes to ensure water cannot get trapped.