Paul & Sabrina's cheap DIY 144v motor controller

[jyanof]

That stuff looks awesome! i liked it so much i just ordered some to tin some copper bus bars I have in my traction pack wiring.

[MPaulHolmes]

Rock on, Joe! Make sure you have some ammonia on hand, and rinse it right after you take it out of the stuff. Also, make sure it's super super super shiny like maybe sand it down a bit with some super fine sand paper like maybe 600 grit? The tin plate looks nicer when it goes on something that's super shiny! But it still works great! I love it!

I tacked on the 0.022uF caps onto the control board underbelly hehe and added the diodes.They are ready to go!

[watt-a-mezz]

Hi paul. Wanted to ask what the temp limits and voltage cutback are. Was also curious about the silver tinning, is that for heat or helping the electricity move easier? We had 90 Degree temps in the shade today, and that would make the parts under the hood REAL warm Take care,Watt

[JayC]

It's for making the task of soldering easier as well as providing an anti-oxidation layer to the copper. Also, it's not silver, it's tin.

[watt-a-mezz]

Originally Posted by JayC

It's for making the task of soldering easier as well as providing an anti-oxidation layer to the copper. Also, it's not silver, it's tin.

Thanks JayC. I've noticed on the Kelly controller the bars do tarnish. Sounds like a real good idea, Plus it does look nice. Take care, Watt

[MPaulHolmes]

Originally Posted by watt-a-mezz

Hi paul. Wanted to ask what the temp limits and voltage cutback are.

Well, I'm not sure what's the best temperature setting. It's super easy to change. Right now I think it's set to thermal shutdown start at 75 degC, and total shutdown at 85 degC. Today it got all the way to like 65 F with rain! haha! I'm glad Joe is getting one, from Phoenix. He'll be able to test temperature extremes.

Man, I had some super nice little electronic needle-nose pliers that were like $20 (made in USA) and now I can't find them anywhere to bend the stupid mosfets/diodes legs. Makes me mad. I went to Home depot to get new ones.

[jyanof]

Originally Posted by MPaulHolmes

Right now I think it's set to thermal shutdown start at 75 degC, and total shutdown at 85 degC. Today it got all the way to like 65 F with rain! haha!

i'm jealous. 106F today. my thermostat in my house is set to 82F during the day, and 79F at night.

Along these lines, the freeway is 2 miles and 4 stop lights from where I work. The other day it was 105F outside and I got a red light at every light. Sure enough, the curtis entered thermal protection mode and limited current to roughly 350A just as I turned onto the freeway onramp (which is inconveniently uphill). 35mph all the way up. Embarrassing.

I'm expecting great things from the Revolt!

[jyanof]

Originally Posted by MPaulHolmes

Also, make sure it's super super super shiny like maybe sand it down a bit with some super fine sand paper like maybe 600 grit? The tin plate looks nicer when it goes on something that's super shiny!

Good tip! I've used a light acid wash on copper to remove the oxide layer and make it all shiny. Toilet cleaner works well. Rinse and dry.

[watt-a-mezz]

hi,jyanof. Hope you got to where you were going wihtout anthing shutting down. The kelly I put in the nissan would be soup in these temps we are having.(and I put 2 fans on it).I believe the Revolt with adjustable settings would do good in any climate. Storm coming, so I better get off this thing. Watt

[MPaulHolmes]

I did a bunch of stuff on Joe's controller today. I found out when I tried to think every piece through, that I made a mistake in how I drilled the 5 holes in the aluminum plate. I had to drill 5 more holes in a different spot (I feel ashamed. ) So, Joe might need to plug those holes with maybe some silicon or something. Here are a few of the 59 pictures I took today:

DIODES:

MOSFETS:




I sanded off a bit of the tin residue stuff since I left the tin salts on it while I ran to the store to find ammonia to clean it. The bus bar that I cleaned off right away turned out way way better. You live and you learn. boohoo.