Arlos Brushed motor controller repair attempts

[Arlo1]

So I went and saw Randy at Canadian EV today and picked up a 48v 300 amp DCX altrax for my golf kart motor to get started and I also picked up a curtis controller and a Zapi controller that need repairs. The Zapi uses 38 irfp260n fets for the brushes and 8 of the same to power the feild coil. I have it apart. I was thinking maybe switching them to irfp4668pbf fets they are ~1.90 ea vs ~4.50 ea from future. I found a blown diode and resistor as well. But the current sensor is pretty cool. Just thinking about what I can do for more power!

[Arlo1]

Ok so I figured out my motor is a series motor lol so the only controller that will work is the curtis. Anyone have software for curtis??? I found this link to upgrade them to 500amp 60v they already have the holes for the extra mosfets.

[Arlo1]

A quick update. The 1204 series curtis controller has a board ready for 20 mosfets. The 225 amp controller I got was ok. It just needed a ground wire from the third leg on the throttle pot which curtis does not show on their wireing diagram. So I added 11 more mosfets and gate resistors and cranked the current limiting pot and she is a ripper! I popped it into a 230lb dune buggy of mine and it launches HARD so hard is scares people. LOL. I have a 1205 which is a longer case to look at as well (more mosfets?). I will try to get some pics up soon.

[salty9]

Arlo,

You might want to check the caps. Tesseract in post 5 in the link below talks of capacitors in DC motor controllers having a miserable existence.

http://www.diyelectriccar.com/forums/showthread.php?t=23799&highlight=controller+alternator

Chuck

[Arlo1]

Arlo,

You might want to check the caps. Tesseract in post 5 in the link below talks of capacitors in DC motor controllers having a miserable existence.

http://www.diyelectriccar.com/forums/showthread.php?t=23799&highlight=controller+alternator

Chuck

I think Im ok. This is a known thing with these over priced controllers. They just install a certain number of fets and gate resistors and charge according to the amp output. It also uses the voltage drop of the fets to watch the current so when you add more the amp rating goes up instantly! There is also a screw for adjusting the current limit and I cranked it. I have driven the off road buggy as well as a few others and it has been perfect so far!

[salty9]

Is that the motor you asked about in the DIYElectricCar forum?

[Arlo1]

Is that the motor you asked about in the DIYElectricCar forum?

Yup

[salty9]

Bonus!

[Arlo1]

Yup I talk more about it here. I am going to work with the kids to make the kart more pretty over the next few weeks. And get it to hold the motor better so the chain doesn't loosen off anymore lol. It would be cool to find more of these motors. It looks like Lemon juice uses 4 simular motors.... Its hard to tell but could be, Im running ~ 1/3 of the power gabreil is claiming to run into his 70,000 watt kart on youtube!

[salty9]

Arlo,

You should name that motor Lazarus. From the picture I saw in your other thread, it looks like you raised it from the dead.

[Arlo1]

Arlo,

You should name that motor Lazarus. From the picture I saw in your other thread, it looks like you raised it from the dead.

Lol yeh. Well it was free and costed me about $15 for bearings and about $3 worth of spray paint. I love it. I need more like it. It was/is a perfact example for the kids to see you dont need money to go fast. The whole kart was done on a shoe string budget and it launches hard! We will be upping the power in the future as well!