I'm not an engineer, but the fact that you're getting leakage when the 
controller is chopping and not when it's full on suggests to my relatively 
untrained mind that some capacitive or inductive coupling might be 
happening.  

You might try rerouting and/or shielding all the high power wiring, 
including the battery cables.  Twist the battery cables together, or at 
least zip tie them parallel to each other.  Make them as short as possible.  
Same with the motor cables.

David Roden - Akron, Ohio, USA
EVDL Administrator

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