Go Back   EcoModder Forum > EcoModding > Fossil Fuel Free > Open ReVolt: open source DC motor controller
Register Now
 Register Now
 


Reply  Post New Thread
 
Submit Tools LinkBack Thread Tools
Old 11-29-2011, 02:36 AM   #5221 (permalink)
PaulH
 
MPaulHolmes's Avatar
 
Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
Posts: 3,831

Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
Thanks: 1,367
Thanked 1,119 Times in 734 Posts
There should actually be about 1kOhm resistance from Gate to source, but drain to source should be large. I would disconnect the bus bars from the battery pack and turn on 12v to the control board, withe the throttle connected. Then I'd check the voltage from any of GR1 through GR10(either side) to the B- bus bar. It should be zero volts. Then with the volt meter still attached, I'd give it a little throttle. The voltage should climb to about 12v, and then drop to zero, and the led should start flashing. Does that happen?

__________________
kits and boards
  Reply With Quote
Alt Today
Popular topics

Other popular topics in this forum...

   
Old 11-29-2011, 03:16 AM   #5222 (permalink)
EV DIYer
 
Join Date: Jun 2009
Location: Vancouver, BC
Posts: 28
Thanks: 8
Thanked 5 Times in 4 Posts
Paul, I will reconnect the controller board to the power board and test the voltage between GR1 thru GR10 and B-. I am getting 3.34M Ohms from drain to source and over the 20 meg scale at gate to source.

Amin
  Reply With Quote
Old 11-29-2011, 04:28 AM   #5223 (permalink)
EV DIYer
 
Join Date: Jun 2009
Location: Vancouver, BC
Posts: 28
Thanks: 8
Thanked 5 Times in 4 Posts
Well, I put the controller together again and checked the voltage from the gate resistors to B-, and it rose from zero up to about 12 volts before dropping back to zero as the LED started flashing. Connected a 12 volt lamp to M- and M+B+(with a second 12 volt battery) and it went brighter as I turned the 5K pot.

I will try it in the car again tomorrow and see what happens.
Attached Thumbnails
Click image for larger version

Name:	004 (1).jpg
Views:	171
Size:	49.5 KB
ID:	9810  
  Reply With Quote
Old 11-29-2011, 10:06 AM   #5224 (permalink)
PaulH
 
MPaulHolmes's Avatar
 
Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
Posts: 3,831

Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
Thanks: 1,367
Thanked 1,119 Times in 734 Posts
Is the DC-DC in the car isolated from input to output? Do you know what sort of isolation rating it has? There isn't a chance that the battery pack ground is shared with the control board ground is there?
__________________
kits and boards
  Reply With Quote
Old 11-29-2011, 01:40 PM   #5225 (permalink)
EV DIYer
 
Join Date: Jun 2009
Location: Vancouver, BC
Posts: 28
Thanks: 8
Thanked 5 Times in 4 Posts
The DC to DC converter is isolated from input to output, but I have no information on the isolation rating -- it's a Kelly 96V to 13.5V, and is switched into the circuit with th same solid state relay as the precharge bulb. The battery pack is not grounded with this setup --only connected to B- and DC/DC negative plus the heater 'negative' as shown in the diagram I attached previously.
  Reply With Quote
Old 11-29-2011, 07:46 PM   #5226 (permalink)
EV DIYer
 
Join Date: Jun 2009
Location: Vancouver, BC
Posts: 28
Thanks: 8
Thanked 5 Times in 4 Posts
Work fine now!

Paul,

I installed the reassembled controller in the Chevy Sprint and did some tests before making all the connections. With just the pack B+ and B- connected, I switched on the relay to precharge, and this time the bulb went on and no more smoke from the vicinity of the controller. With a 7 watt bulb the precharge time was 25 to 30 seconds, so I replaced it with a 40 watt one and that cut it down to about 6 seconds. I had set the controller precharge time at 7 seconds, so this was perfect.

Completed all the connections, checked and rechecked them and then switched it on. The precharge bulb came on, dimmed off and I heard the contactor close. Pressed the throttle pedal and heard the motor rev up genlty. As the front wheels were raised up off the floor on stands, I put it in gear and ran it a little and it seemed to run fine.

I'll do a test drive after I tighten all the connector bolts and nuts.

Amin
Attached Thumbnails
Click image for larger version

Name:	017 (1).jpg
Views:	171
Size:	53.1 KB
ID:	9812   Click image for larger version

Name:	028 (1).jpg
Views:	166
Size:	111.3 KB
ID:	9814  
  Reply With Quote
Old 11-29-2011, 09:57 PM   #5227 (permalink)
PaulH
 
MPaulHolmes's Avatar
 
Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
Posts: 3,831

Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
Thanks: 1,367
Thanked 1,119 Times in 734 Posts
That was mysterious! Oh please don't blow up... That sucker looks beautiful. How did you do the end caps?
__________________
kits and boards
  Reply With Quote
Old 11-29-2011, 10:34 PM   #5228 (permalink)
EV DIYer
 
Join Date: Jun 2009
Location: Vancouver, BC
Posts: 28
Thanks: 8
Thanked 5 Times in 4 Posts
I had the rear connector cover panel from a 37" ViewSonic TV which happened to be about the same height, so I cut a piece from each end the width of the case and filed the edges to fit. Since it is a fairly soft ABS plastic, I was able to shape the rectangular holes with an exacto knife after drilling small holes around the outline. They are not yet glued in -- just held together by being pressed on with zip ties on the bus bars. I also shortened the case cover and the M- bus bar by an inch. Used an old table saw with a metal cutting disc in place of the blade -- works on plastic too! I had managed to get the current sensor closer to the circuit board by cutting the steel bar short so it would slide over the insulator board.

The smoke was probably not from the controller. I suspect a momentary short circuit across one of the 12 volt wires near the back of the controller, although I could not find any trace of a burnt wire anywhere -- probably vaporized.
Attached Thumbnails
Click image for larger version

Name:	049 (3) (1).jpg
Views:	155
Size:	68.2 KB
ID:	9815   Click image for larger version

Name:	007 (1).jpg
Views:	141
Size:	64.6 KB
ID:	9816  
  Reply With Quote
The Following 2 Users Say Thank You to amino For This Useful Post:
madmike8 (11-30-2011), MPaulHolmes (11-29-2011)
Old 11-29-2011, 10:45 PM   #5229 (permalink)
PaulH
 
MPaulHolmes's Avatar
 
Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
Posts: 3,831

Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
Thanks: 1,367
Thanked 1,119 Times in 734 Posts
Very nice work.
__________________
kits and boards
  Reply With Quote
Old 11-30-2011, 01:51 PM   #5230 (permalink)
EcoModding Lurker
 
Join Date: Nov 2011
Location: Texas
Posts: 2
Thanks: 1
Thanked 1 Time in 1 Post
Lurking!!!!

Great work guys! I'm building an 88' toyota pickup, has no motor, so i would rather spend the money to convert it to electric (inexpensive as possible, of course) than put an ICE back in. I have a good supply of batteries and this controller will work well for me.

I've been reading from page 1, after about four days of reading i'm only at page 101! I know I have a long way to go, but i'm the type of person that needs the back story.

Thanks to all of you for the work that has been put into this.

  Reply With Quote
The Following User Says Thank You to BlueBlood For This Useful Post:
MPaulHolmes (11-30-2011)
Reply  Post New Thread


Thread Tools


Similar Threads
Thread Thread Starter Forum Replies Last Post
Paul and Sabrina's Cheap 3 Phase Inverter (AC Controller) with Field Oriented Control MPaulHolmes Fossil Fuel Free 3472 01-12-2021 05:47 PM
Paul & Sabrina's Cheap EV Conversion MPaulHolmes Fossil Fuel Free 542 11-12-2016 10:09 PM
Three Dirt Cheap DIY Electric Cars - Part 5 SVOboy EcoModder Blog Discussion 0 12-12-2008 05:10 PM



Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2021, vBulletin Solutions Inc.
Content Relevant URLs by vBSEO 3.5.2
All content copyright EcoModder.com