Paul & Sabrina's cheap DIY 144v motor controller

[ElectricZX2]

Thanks Greg....I'll look into that.
For now, I got realterm up and running with the help of Paul (Thanks!). Unfortunately I couldn't get any driving data because I didn't have a long enough cord.

It was funny...I had to download with my wife's computer that has internet, burn a disc with my old computer that doesn't have internet, and install on my oldest computer that doesn't have a usb drive but has serial...ha.

Anyways, here are the stats after an 11 miles drive through town with lots of stop and go. Didn't push it too hard but didn't take it easy. Always wish I had regen through town...
Only thing I'll check on later with a multimeter was VO =128...pack voltage should have been closer to 137 at that point (main contactor was open but precharge circuit was closed, would that be the difference?). Average pack voltage during the drive was probably right at about 138-139.
Also, can someone convert the temperature for me?
On interesting thing was that tr only goes between 0-238 rather than 0-511. I haven't pushed the pedal anywhere near the metal but I'm wondering if I'll see 1000amps at full throttle....I guess we'll see.

CF=002
HS=0464
RT=718
AH=015.0
VO=126

[ElectricZX2]

Also, I should clarify....ambient temp was about 30C.

[ElectricZX2]

Also, will rtd explorer run on win98? I tried installing it and got a message telling me that the program is expecting a newer version of windows...

[Greg Fordyce]

The 4D systems display I am using for the Cougard Explorer has a freely downloadable development environment for Windows. Linux and Mac aren't supported although I think some people have been able to use it on Linux with Wine. I am using a netbook running Win7 Starter. I think Rtd Explorer requires at least XP. I find it freezes quite often with Win7, anyone else had this problem?

For linux you can use moserial as a terminal program to communicate with the controller. I posted some setup instructions in this thread a while back.

Greg

[ElectricZX2]

Now if someone would develop an android app that would be awesome!
I drove home a different way today...less stopand go and some stretches of constant 45 and a stretch of 3 miles at 50 mph. Heat sink went from 36c to 53c at its peak. I'm sure highway temps would be hhigher. Gave it full throttle and only saw tr of 286. Didn't feel like 1000 amps so I'm thinking something isn't right....pot measures 0-5.2kohms though on the multimeter.
Trip was 10.5 milesand used 14.4 ah @ 135 volts average. was doing well for a while and then got cut off by a sportscar and pursued for a bit. After that i decided to do the full throttle test

[adamj12b]

Originally Posted by ElectricZX2

Also, will rtd explorer run on win98? I tried installing it and got a message telling me that the program is expecting a newer version of windows...

No, RTD explorer uses the .net framework and will not run on windows 98. Windows 2000 minimum.

I have not had any issues running on win7. We actually program RTD Explorer on win7.

-Adam

[duncan]

Hi Guys,
I got the controller kit as a Christmas present - the weather was too good then but winter arrived a couple of weeks ago so I have been using the kitchen table to build the thing.

I have followed the instructions - page 19 worried the hell out of me, I have been using a sharp pointed 25w iron with a sort of magnifying visor thing being very careful to use the minimum solder - and I'm not sure if I have done it right

I was happier with the big stuff - used a 200w iron!

Its all complete and its time to test it

Looking at the wires soldered into the J1 holes
From right to left
12v +ve
12v -ve
I don't know what this wire does
Twisted pair for throttle 1
Twisted pair for throttle 2

So I should - attach a 5K pot to the twisted wires
12v +ve, 12v -ve

What do I do with the other wire?

What should light up?

Is the microprocessor already programmed with something?

[mora]

The unknown wire is for contactor control. When you get to fine tuning stage (using RTD explorer or such) you can set the delay after which it outputs +12V. It is intended to close main contactor after preset amount of seconds after controller is turned on. There might be a pre-set value if your chip is preprogrammed. You don't have to connect that contactor control wire anywhere.

Connect your controller to a computer if you can. You could download RTD explorer and see if your controller output serial data. You'll get some nice real-time graphs and ability to tune different parameters. No serial output - problems. Oh, there are two leds that are supposed to lit when controller is powered up. Then it is o'scoping gate resistors for proper signal. I didn't do it, I was happy with serial output and went to test the controller with motor and 12V starter battery. Don't connect your full pack voltage there right away, simple 12V test should be safe. Use separate batteries for powering controller and motor.

[Bill Tuttle]

Wow - finally through all 505 pages! Of course, now that I'm to the end I find myself asking, "Should I be considering AC maybe?" Off to the next thread I guess!

Thanks guys for a very informative and entertaining read! Trying to gather as much info as I can before starting on our EV next year.

Can anyone point me to a good AC vs DC article or thread? Thanks!

[electricstorm]

@ Adam,

RTD Explorer uses an RS-232 serial port to program the Couger controller. My computer does not have the RS-232 port. Can you use an RS-232 to USB adaptor of some sort? If so, do you know what type or version (I have seen the C-233-M and TU-S9 chipset versions) I should use? If not, how old of a laptop should I look for (also, should it be Windows XP, Vista, not sure if windows 7 models have an RS-232 port or not)?

Thanks,

Jim