Paul & Sabrina's cheap DIY 144v motor controller

[LouMan]

Kool getting anxious to start building it hehe

any words about ver.d boards on page 226, the upgrades look great!!
let me know when I can order one hehe.

[MPaulHolmes]

Hey Lou! You'll have to talk to mcudogs. I think he ordered some.

[apowers]

I got all the rest of my parts today. Now I am ready to start the assembly.All except the cables that connect the current transducer to the PCB and thermister to PCB.and the connectors that plug them in. These parts are not spec on the BOM. I'll figure it out.
But there will be dumb questions to follow. Wish me luck.

[esoneson]

Good luck apowers.
Let us know how it goes......good, bad and ugly.
My non-soldering-fingers want to know.

Eric

[MPaulHolmes]

Hey Alvin! I've been soldering the wires directly through the control board holes. It works well. You also need little crimp pins. You get them at digikey:

Part number: WM1114-ND

Then you need the 4 pin housing that the pins go into so it can plug into the LEM. I can't find that stupid part number anywhere.

[apowers]

Thanks Paul
I looked on the data sheet molex 5045-04a.
Is the cable from LEM shielded?
Also is the contactor control programed?
Thanks
Alvin

[mcudogs]

Originally Posted by LouMan

Kool getting anxious to start building it hehe

any words about ver.d boards on page 226, the upgrades look great!!
let me know when I can order one hehe.

I have posted the PCB files on the WIKI. If you want to order a set, I am about to place an order with PCBCART. It should be about $AUD9 for controller boards and $AUD18 for power boards plus postage.

These will be prototypes and may need some mods. The version C boards are proven.

[MPaulHolmes]

Hey Alvin! Yes, shielded cable for the LEM. Attach one end of the ground wire inside the shielded cable to system ground, which is one of the LEM pins.

The engineer that did the first 3 assembled control boards wrote to me about the missing part numbers:


The 4 pin housing that plugs into the controller is 22-01-3047 . The housing that plugs into the LEM header is 22-01-1042.
It's a bit narrower than the other 4 pin (.098" pitch versus .100"). They both use the same crimp pins though.

5 pin Molex 09-50-8053
4 pin Molex 22-01-3047 (to LEM)
3 pin Molex 22-01-3037 (rs-232)

crimp pins for 3 & 4 pin housings above.
08-50-0114 This accepts wire from 22-30AWG

crimp pins for 5 pin housing
08-50-0134 This accepts wire from 22-26AWG
08-52-0072 This accepts wire from 18-24AWG

COULD SOMEBODY ADD THESE TO THE WIKI? I would, but I don't feel like it! hahahaha.

[adamj12b]

Hi Guys,

I have finally got my controller up and running!!

Here are some pictures and a video of the initial golf cart run!

Assembled Top:


Assembled Bottom:


Control Board:


Internals:

* The little connector sticking up near the B+ bus bar is the thermal sensor sticking out of the heat sink.

Right Side Up with Enclosure Cross Section:


Dual Driver Board:



And the video!!!

http://www.youtube.com/watch?v=CCGFjGTuwlE

I hope you enjoy!!

Sorry for the simple post, I am running out the door now and this is all I had time for.

-Adam

[TheSGC]

Wow, Adam that is looking good!

Yeah, a golf car isn't going to stress that beast of a controller, unless you try to climb some mini mountains or something.