View source for Talk:Gen1/Alltrax Controller

Alltrax Controller 4855 damaged (~ 5000 km) repair needed.

Own DC Controller Design:

IGBT Semikron Semitrans SKM 400GA 122D
{| class="wikitable" border="1"
|-
|-
| V_CES
| 1200
| V
|-
| I_C @ 25°C
| 400
| A
|-
| V_CE Sat @ 25°C IC typ.
| 3,5
| V
|-
| P_tot @ 25°C
| 2500
| W
|-
| Case
| D32
| [https://www.datasheetarchive.com/pdf/download.php?id=e8d53ab0445b81aa6100766d50cdfde27cbdcf&type=O&term=IGBT%252BSKM%252B400%252BGA%252B122D%252BSEMIKRON Datesheet]
|}

DIY DC 80V 400A Controller Schematic v1.0:
[[File:DCController.jpg|thumb]]
Arduino Generates PWM Signal into the IR2181 IGBT Driver.
Tested with 25V and 5A

DCDC Power Supply: Mini XL7015 DC6-80V Input - DC5-20V Output

=== First Test ===

DC Motor did rotate

after ~30 sec IGBT burned (got too hot) @ ~5% Throttle

IR2181 IGBT Driver also burned, due to low resistance between Gate and Source

Conclusion:
* Insert safety fuse on board
* use current limiting (shunt or coil measurement)
* Temperature sensor emergency cut off


=== Alltrax and Wiring Information ===

3 Control Wires (18AWG) and 2 Power Cables (3AWG) from Battery Pack.
CRTL-1 (18AWG): Battery + (~58V)
CRTL-2 (18AWG): Throttle 0-3V
CRTL-3 (18AWG): Ground

Alltrax Controller Features:
* Bicolor LED red and green
* supports 7 different throttle types: (Green Blinks on startup) (1) = 0-5k ; (2) = 5k-0 ; (3) = 0-5V ; (4) = EZ-GO inductive (ITS) ; (5) = Yamaha  0-1K ; (6) = Taylor-Dunn 6-10.5V ; (7) = CLUBCAR 5K-0, 3-wire 
* Checking for Throttle Sensor Over Range. Check for open wires.
* Checking for Under Temperature. Controller below -25C.
* Checking for HPD (Hight Pedal Disable).  Throttle hasn't gone to zero during this power on cycle.
* Checking for Over Temperature.  Controller over 95C.
* Battery Under Voltage detection. Battery V < undervoltage slider.
* Battery Over Voltage detection. Battery V > overvoltage slider.
Programming Features:
* set max. current output (%) max. 400A AXE4855
* set Under Voltage (V)
* set Over Voltage (V)
* set Throttle Up Rate (1-15)
* set Throttle Down Rate (1-15)
* set Brake Current (%)
* set Top Speed (%)
* disable/enable HPD
* Throttle response setting Linear, S-Curve, Progessive, Inductive
Monitoring Features via RS-232:
* Throttle Position (%)
* Controller Temperature (°C)
* Battery Voltage (V)
* Output Current (A)
* Battery Current (A)
* Error Flags

=== Todo ===

* Picture of the CTL1 CTL2 CTL3 CTL4 Cables going into the Alltrax
* Alternative DCDC Motor Controller Open Source
* Wireing Diagramm Alltrax DC-Motor