Damians github controller

[Bimmerbaz]

Hello,
I am new to this forum . I am in New Zealand and i work in the training side of the auto industry. I am working on making one of Damians DC controllers . I am currently getting the boards mafe and sourcing the components. I am having trouble identifying the large cap and the 2 smaller ones on the bus bars as shown in the E36 controller build. Can you let me know the values or part numbers for them.
Thanks Barry

[Jack Bauer]

Damien needs a holiday, a pay raise and about 5 full time engineers on staff.

You need two types of capacitance in any motor controller or inverter. One is a big slow lumbering beast to cancel the inductance in the power leads. Like this :
https://www.ebay.co.uk/itm/4700uF-400V- ... 5020592102

Then you need a small and fast variety to catch the di/dt spikes like this one :
https://www.ebay.co.uk/itm/KEMET-NISSEI ... 8024273459

Of course it's possible to combine both into something like this but more expensive :
https://www.ebay.co.uk/itm/AV-C4DE-270U ... 2294635360

[Bimmerbaz]

Damian need a medal for his sterling work. If i lived close i would be your engineer .

Thanks very much for the info.

Cheers Barry

[Jack Bauer]

Glad to help

[Bimmerbaz]

Hello again.

I am building a DC motor controller and wondered if you could tell me the Lem Current sensor part number that shows in Damians videos. I have one out of an old prius but it only has 3 wires and i cant find a data sheet for it to make it work with the 4 wire controller logic board.

Cheers Barry

[Jack Bauer]

LEM HASS 300-s

[Bimmerbaz]

Thank you once again . I am nearly complete on the construction and hope to start testing soon. I also have the motor mounted to the gearbox ready to go back into the vehicle. Taking small steps.

Cheers Barry

[Sri]

Hi
I am also new this forum i am trying make controller with igbt
And with big capacitor and snuber caps
I want some help for logic board with 4 layers i dont under stand
1234 layers Gerber file
Logic bord Gerber file it's 4 layers or 2 layers

Help me for inner second and third layer,
Thanks

[Jack Bauer]

the logic board is 4 layer. Inner layers are +5v and gnd.

[Sri]

Thank you Jack bauer
Please any body know on logic bord which one is the first/second/third/ fourth copper layer,
Thanks very much for the info

[Sri]

Thank you Jack bauer
Please any body know on logic bord which one is the first/second/third/ fourth copper layer,
Thanks very much for the info

[Sri]

Thank you Jack bauer
Please any body know on logic bord which one is the first/second/third/ fourth copper layer,
Thanks very much for the info

[Bimmerbaz]

Hiya,

I am at the testing stage of the controller and i have a small issue with the throttle potientomer. I have got a poteniometer from a golf cart that seems to work fine. When i check the output of the PWM it only works in a small range of the potienimeter . Do ineed to change the resistor in the logic board to make the range better?

Cheers Barry


https://photos.app.goo.gl/bJpiGo6jdfPJGegT8

[Sri]

Hi Barry
I am also new in forum did you know that logic bord Gerber file
ground is 2 layers and +5v is 3 layer is it correct ?
If you have logic bord components i can buy
Thanks
Sri

[sonachan1]

I am at the testing stage of the controller and i have a small issue with the throttle potientomer. I have got a poteniometer from a golf cart that seems to work fine. When i check the output of the PWM it only works in a small range of the potienimeter . Do ineed to change the resistor in the logic board to make the range better?

Hi Barry,

Looking at the video I think things are generally working as expected. When the throttle input is low there's no PWM, there's a bit of deadband before anything happens and you get maximum output when the pot's at the opposite end.

A couple of things spring to mind. Firstly, the throttle pot should be connected across the 5V supply, so regardless of what's going on in the circuit, you should be seeing 5V at the throttle signal input at one end of 'throttle range. Have you had a look inside the box to see what's in the throttle box? There might be a couple of additional resistors depending on the original application. Maybe connect a different pot temporarily to see what happens?

Secondly, diodes D2-D4 provide the deadband I mentioned above. The throttle input has to forward bias the diodes before the signal is seen by the PWM generator. In reality this means you have to press the throttle a bit before you start moving.

Personally, I wouldn't worry about it too much for now, carry on building and see what the throttle response is like before making any changes. I've got this circuit on my controller PCB and its doing a similar thing. I'm trying to get my controller up and running so I can see what happens!

[sonachan1]

Hi Barry
I am also new in forum did you know that logic bord Gerber file
ground is 2 layers and +5v is 3 layer is it correct ?
If you have logic bord components i can buy
Thanks
Sri

Hi Sri,

Damien's logic board is 4 layer. The two internal layers are +5V and Gnd. The exact order of the internal layers is not important in this application. The copper layout on each layer will connect everything up correctly!

[Jack Bauer]

This board was not designed to work with a throttle pot but rather a hall effect throttle pedal such as those used on the BMW E46.

[Sri]

Hi Sonachan
Thank you so much for the layers info
Now i can buy the components
Best regards
Sri

[Bimmerbaz]

This board was not designed to work with a throttle pot but rather a hall effect throttle pedal such as those used on the BMW E46.

Thank you very much for the info Jack and also thank you very much for sharing you knowledge, I have just had the 1st test of the controller and it works. I need to change the throttle and wire up the current sensor but it works .

Cheers Barry

https://photos.app.goo.gl/Gow1vJPEz2EhCGqd8

[Sri]

Hi
Need help
I am making igbt bord now , components list R1 R2 R7 R8 resistance 22 oms 2w but on schematic pdf its 10 oms
What is the exact value resistance ?
Thanks you
Regards
Sri

[Jack Bauer]

Depends what igbts you are using and how fast or slow you want to switch them:)

[Sri]

Thanks Jack bauer
I am using igbt mbm600gs6c for motor 24vdc
Best regards
Sri

[jo9nisingt35r]

hello
wonder if anybody has spare pcbs for sale ?
thank you

[Jack Bauer]

Boards are available on my webshop : http://www.evbmw.com/index.php/evbmw-we ... -bare-pcbs

[Sri]

Hi
What is the resistance value on the precharge R1 R2 2w
Example for 24v 200 amp
And precharge resistance value on the contacteur please
Thanks