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[Doctorbass]

Improved power!

41kW !!

I measured 638A at 64.1V =40.895kW of power to the motor

That's 55hp in the motor!! i saw that burst at about 60km/h.

I guess at the Wheel i probable have about 80% of that = 44hp...

The 2012 s stock have 30kw to the motor i gained 33% higher power by using the size 6 =)

That is awsome!!

Doc

[Nuts n Volts]

Doc, have you tried to source a lower voltage size 6 and then run >660A to the motor. I know the motor can handle more current. It wouldn't be as efficient as the 28s version, but it could have the same power.

I have also seen about 640A battery peak from my size 6 controller. Measured with a CA. Something like 62kW (97V sag) into the controller.


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[Doctorbass]

Well i am not so sur ethe lower voltage version can do higher amp... let me explain.
 Driving a controller lower than his rated voltage help for mosfet protection. some controller fet see sometime as high as 1V per 10 amp overshoot when they switch ON and OFF. so when using higher current it also mean it require better voltage tolerance to sustain the high phase amp...

otherwise ... did you heard that the 48V model was able to drive higher than 660A?

Doc

[Nuts n Volts]

I understand what you mean, I trust that both Sevcon and Zero have done the hard work of making sure they have appropriate limits set on software so that the controller will not become damaged.

Yes the 48V size 6 does 780A.
http://www.sevcon.com/media/2461/Gen4%20Aug%202013%20web.pdf

Never seen one In the wild, but I believe that they make them.


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[protomech]

G48 max operating voltage is 69.6V, that's 3.87V per cell.

[Nuts n Volts]

G48 max operating voltage is 69.6V, that's 3.87V per cell.

I didn't even think about that. I assumed the 18s Zero used a lower voltage sevcon, but never took 5sec to do any math. I guess Doc will just have to go dual controllers to get more power.


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[protomech]

G48 max operating voltage is 69.6V, that's 3.87V per cell.

I didn't even think about that. I assumed the 18s Zero used a lower voltage sevcon, but never took 5sec to do any math. I guess Doc will just have to go dual controllers to get more power.


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Nope! Same controller from 2012-2016!

At this point it's almost the only part of the bike that's the same, except the headlight

[GBEV]

Add an R to an S or DS and pay an extra $2000 for the R badge and another 240 amps? What else?
That is the additional cost you pay to go from a 420 to 660 amp controller so for 240 amps more!
Thicker wire, bigger box and a few more mosfets and possibly an economy of scale.
Does anyone know why that +$2K should be?
As Sevcon are made in England would anyone like me to try get a price for a job lot?

[Doctorbass]

Add an R to an S or DS and pay an extra $2000 for the R badge and another 140 amps? What else?
That is the additional cost you pay to go from a 420 to 660 amp controller so for 140 amps more!
Thicker wire, bigger box and a few more mosfets and possibly an economy of scale.
Does anyone know why that +$2K should be?
As Sevcon are made in England would anyone like me to try get a price for a job lot?

Maybe you should correct you math! this is NOT  140.. that's 240A more =) ..... just like a Size 4 and a size 2 together... that's 55% more and it WORTH !!

Doc

[GBEV]

Yup, Math corrected Thank you.
Point still stands though $2K more for an extra 240amps through the controller?
I am sure that looks like a great deal to an ICE bike tuner and the bike will no doubt go faster once out of the restricted zone but what exactly costs an extra $2000 in a Sevcon 6 contriller compared to a 4 is my question?

[protomech]

Yup, Math corrected Thank you.
Point still stands though $2K more for an extra 240amps through the controller?
I am sure that looks like a great deal to an ICE bike tuner and the bike will no doubt go faster once out of the restricted zone but what exactly costs an extra $2000 in a Sevcon 6 contriller compared to a 4 is my question?

From a cost perspective, very little. The controller price from Sevcon is not significantly different, certainly not by $2000.

Ex: here are a couple resellers that list prices. Zero's prices will be somewhat lower of course.

Size 4 975 €
http://kartmasters.fr/shop/fr/variateurs-triphases/835-variateur-sevcon-gen4-8035.html
Size 6 1323 €
http://kartmasters.fr/shop/fr/variateurs-triphases/836-variateur-sevcon-gen4-8055.html
Various Size 4 $875, Size 6 $979
http://www.thunderstruck-ev.com/ev-controllers.html

I don't doubt Zero has considered offering Size 6 controllers for all bikes, presumably at a lower cost but perhaps with different motors, as Brammo has done with the Empulse. Offering a 50 kW bike at a lower price would certainly increase sales, but overall profit might go down because the $2000 markup between S and SR is almost pure profit. Their business types have crunched the numbers and what they're shipping represents what they think to be the optimal mix.

Is that the best for the consumer? Perhaps not, but given the proportion of SR sales, enough people see perceived value in the size 6 upgrade to pay the difference. And certainly a bike manufacturer that goes under due to an unsustainable business model is not in the owners' best interests.

For the people that want to buy a Size 4 and upgrade to a Size 6 later, they can go Doc's route or contact Hollywood Electrics for an upgrade kit.