Paul & Sabrina's cheap DIY 144v motor controller

[flores]

No its the controlboard..

This is all the stuff I got from Paul today:


And I'm pretty sure this is not meant to be like this:



And these are broken for sure:



And these are really close together.. better separate that more:



Paul, could you give me the mouser numbers of those caps? I'll order some new ones..

[MPaulHolmes]

The last picture is the reason for the kapton tape. The tape enables a larger amount of copper to remain for carrying current.

I'll ship you some from mouser.

[flores]

I guess the shipping costs will be excessive.. that's a waste.. I'll order some from here.. will any 100uF 35v do? Or are they special?

[MPaulHolmes]

The real current surge comes from the three 4.7uf MLCC caps. So, they may well be unnecessary. I had picked a low ESR type, but I think anything would work.

[flores]

Paul,

Can you share some info on what goes where regarding to the B+ B- and M+ cables?

[MPaulHolmes]

They are uploading to photobucket right now. Let me see if they are done...

dc-dc mounting. Use two 0.25" spacers per hole included (so it's 0.5" away from the aluminum enclosure):


Make sure that connection is made before closing everything up. It's for desaturation detection in a short circuit situation. NOTICE THE KAPTON TAPE!!! That's to avoid the short circuit that you noticed would happen.:


M+ cables:


B- cables. The lugs lay flat against the B- copper sheet:


B+ cables. Notice they make a connection to the copper sheet underneath. So, use the lugs that have been bent slightly so they can mount through the hole, but don't touch the B- sheet:


All of them together. Upper left 2 are B+. Upper right 2 are B-. Lower 3 are M+:

[MPaulHolmes]

Duncan, I tested yours in my golf cart. If the code needs tweaking, you will need a pickit2 or 3. They are like $35 or so. It drove around without any problems, but it was a very limited test. I'll make sure the big capacitor is mounted so there are no problems like flores had. It will probably go out by tomorrow. My wife is gone with a herd of children to Costco and other places right now, and I don't think they will be back before the post office closes.

[flores]

And the M+ are the ones that need to be a certain length before coming together?

What was that length?

[flores]

Originally Posted by flores

What was that length?

I've found you mentioned 3 feet somewhere.. is that still correct?

[MPaulHolmes]

I used around 3ft each. just make sure they are the same length. basically, cut the long cable into 3 equal pieces.