Paul & Sabrina's cheap DIY 144v motor controller

[JoeG]

Hey DJ,
I was searching under Thermo-O-Disc and was only getting the made in the USA stuff. When I searched as you suggested under temperature switch, man what a difference. I ordered a couple of the 35C NO China Mfg switches for $5 delivered. It's a good thing I'm not in a hurry, because they estimated 3-4weeks delivery. I figure to test them out with my heat gun and temp probe to see how they work. If ok I'll wire the controller fans with one and save the other for possible use as way to turn on a motor blower if it's needed. Well, this weekend it's back to working on mounting the controller. I have that job about half done. Last weekend I was rained out and they say it might rain here in LA again this weekend.
Thanks again for all the info,
Joe

[jyanof]

Mileage update!

I've been running on my new lithium cells for a couple months now and have started putting on miles again.

I now have 8500 total miles on the controller and 11,500 miles all electric. There's only been the one glitch during that time and it's been documented in the wiki.

[MPaulHolmes]

You sneaky little bugger! hahaha. I'm glad it's still working. What size pack, and what range?!

[jyanof]

Originally Posted by MPaulHolmes

You sneaky little bugger! hahaha. I'm glad it's still working. What size pack, and what range?!

45x CALB 180's - My most efficient run has been 60 mi on 105 AH which suggests a max range of just over 100 mi. Practical range is probably 70-80 mi.

[bjdEV]

Paul,

I have been reading the post here and have recently joined the forum. I am planning my build and have decided on the 144V, 500 AMP configuration using the cougar controller.

Would like to start purchasing some of the cheaper parts. For this system, what specs should the contacter have? I have found some listed with the KTA parts list, but not sure which? Also any suggestions on the circuit breaker?

Any advise would be appreciated.

Thanks
bjdEV

[JoeG]

Do a search on ebay for Tyco Kilovac Contactors, P/N EV200AAANA. They can be had new for $70 shipped, most of the time.
Joe

[bjdEV]

JoeG,

Thanks for the advice. I am new to this and don't have the background for some of the finer technical stuff (like telling the difference between contactors). The part number helps a great deal.

thanks

[isaac_alaska]

we used the tyco in our snowmobile and welded the contactors together pretty solid. then we found out that the logisystems motor controller we were using didn't do any kind of pre-charge and the pre-charge resistor we had installed across the contactor had broken in shipping. as long as you have precharge set up right (which the revolt handles very nicely) it's a great little contactor

[bjdEV]

Issac,

Thanks for the info...I am just beginning to understand how the whole thing works and advice from others will make or break this project. I have high hopes for a successful build.

Thanks

[MPaulHolmes]

JoeG, the Karate Kid was from Reseda too!!