Difference between revisions of "Talk:Gen1/Alltrax Controller"

Latest revision as of 19:03, 9 July 2020

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

Own DC Controller Design:

IGBT Semikron Semitrans SKM 400GA 122D

DIY DC 80V 400A Controller Schematic v1.0:

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