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Old 10-16-2012, 02:08 PM   #16 (permalink)
Ryland
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higher end speed controllers step back the throttle as they heat up to prevent damage to the controller cheaper controllers just shut down when they reach their limit, 500 watts at 24v is only 20amps, a cheap hill climbing option would be a double pole double throw switch that would allow you to switch to bypass the speed controller all together to eliminate the controller over heating issue, the double throw switch would allow you to cut power to controller and a fraction of a second later have full power going to the motor without the speed controller being in the way, before solid state speed controllers a simple on off switch or a few switches hooked up to different strings of batteries was common, it's hard on the motor to give it full power from a dead stop but once the motor is up to full speed/power it's not going to care and going this route is going to cost you about $15 in switches and wire, I'd opt for a 30amp switch, a single pole double throw switch would work as well, switching the positive side, but switching both legs is better.
Going with a higher amp speed controller shouldn't burn out the motor.
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