Paul & Sabrina's cheap DIY 144v motor controller

[jedsmd]

Originally Posted by Crossdan

I have another question about the pre-charge connection. After the pre-set time I get the 12volts between the +12v and middle terminal of J1. However when I attach a relay it won't pull down. I eliminated all wiring thinking the resistance was too high and jumpered directly to a small pcb mountable relay. Still no luck. Anybody have any ideas?
Thank,
Dan

Crossdan
Shouldn't the 12 volts be measured between the middle terminal and ground?

12v measured between +12 and contactor would indicate that the contactor pin was low and had not turned on.
Jerald

[Crossdan]

Paul,
No worries. I'm already ahead of the game by having a controller that I can replace components on (assuming they're bad).
Just to make sure I don't have bigger problems, after the pre-charge timer expires I should record 12 volts between the +12v and the contactor, correct?

Jerald,
At no time, either before or after the pre-charge timer expires do I get 12 volts across the contactor (middle) terminal and ground. I'm hoping Paul doesn't tell me I have bigger problems.

I have my car on jacks waiting for the controller to spin the wheels. I'll try to install this weekend with a 24 v pack to test the motor control portion of the OpenRevolt. If that doesnt work then i definitely have bigger issues.

Dan

[jedsmd]

Originally Posted by Crossdan

Paul,
No worries. I'm already ahead of the game by having a controller that I can replace components on (assuming they're bad).
Just to make sure I don't have bigger problems, after the pre-charge timer expires I should record 12 volts between the +12v and the contactor, correct?

Jerald,
At no time, either before or after the pre-charge timer expires do I get 12 volts across the contactor (middle) terminal and ground. I'm hoping Paul doesn't tell me I have bigger problems.

I have my car on jacks waiting for the controller to spin the wheels. I'll try to install this weekend with a 24 v pack to test the motor control portion of the OpenRevolt. If that doesnt work then i definitely have bigger issues.

Dan

CrossDan
I think there is a software switch that needs to be set before the contactor will work. Other people have written about having problems with it. Hopefully someone more familiar will chime in....
Jerald

[MPaulHolmes]

oohh!!! Could that be what it is? Have you reprogrammed the precharge time? The default is "disabled". You would have to type something like this while the serial communications is going:

pc-time 80
save

That would set the precharge time to 8.0 seconds. Then the yellow wire would go from 0v to 12v after 8 seconds.

[Crossdan]

Sorry, maybe i confused things. I HAVE programmed the pre-charge. After 8 seconds it goes from 0 to 12 volts.
The question is:
Should the 12 volts come from contactor (middle) terminal and ground.
Or from contactor (middle) terminal and +12v supply. (this where I'm getting the 12v)

I just don't get enough amps to pull down the relay.
Dan

[Crossdan]

Or, to put it more simply.
Do I hook up my relay to the yellow and red wires or yellow and black wires?

[MPaulHolmes]

yellow to black

[Crossdan]

I only get the 12 volts from yellow to red.
Think I may need to start with replacing the P channel Mosfet and Optocoupler.

[jedsmd]

Originally Posted by Crossdan

I only get the 12 volts from yellow to red.
Think I may need to start with replacing the P channel Mosfet and Optocoupler.

Dan
Are you measuring the 12volts between the yellow wire and the red wire before the 8 seconds? after the 8 seconds? or both?
Jerald

[MPaulHolmes]

I had put a controller together for a guy over a year ago for the 24 hours of LeMons (lemons, like junky cars). It's the first ever electric that they have ever done. It's on a real life racetrack with people in the stands and everything! He just took it for a maiden voyage tonight. Nothing blew up!

There's an update at the bottom of this page here:
Got the Go-ahead from HQ for my IoE idea (Page 10)