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Originally Posted by Piotrsko
in a normal highway condition you will be only using a couple hundred amps, so the warp will be running fairly cool depending on ambient.
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I use over a hundred amps cruising at 15 mph in a golf cart. But it's at 48V. What voltage are you running?
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my Kostov is hot to the touch running 450 ish watts/mile in the ranger, and in Summertime Reno i have never set off any of the high temp alarms i installed.
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What are your high temps set for?
I have read Netgain motors' recommendation for the brush temperature, for their racers. George Hamstra is on record with a limit of 280C, after which the brush material loses structure and starts to .. peel?
I have not heard of a 'do not exceed' temperature for the motor itself ... unless you count the Class H insulation of 180C .. I think it's 180C
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You want to gear for say 2500 rpm at highway speed, more than 3000 leads to premature brush failure.
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What would premature brush failure be? 10,000 miles or 50,000 miles or 100,000 miles?
Higher rpm uses less amps at higher voltage .. and heat is proportional to the square of the current .. so if I can I will keep the revs higher and the current lower.
A set of helwig red-top split brushes is about $200, from EVTV, for the Warp 11. That is not cheap, but getting the brushes changed will cost more. HOWEVER .. it would be a PITA to get the motor out of my car for the rebuild if there is carbon dust to be removed instead of just replacing the brushes ... and if the carbon is built up over a short time the dust will create other problems, I think.