connect external controller to 400w Kollmorgen

[tno]

any help in connecting this controller to a Kollmorgen motor.
the Yellow, Green, Blue wires in the picture are labelled A,B,C.

Which wires are these connected to in the Kollmorgen which has Red, White, Black wires in order for the motor to spin in the correct direction when attached to a USPD kit?

 

[tno]

Also, how would the Hall sensor wires be connected?

the Kollmorgen was previously connected to a transmag controller as seen in the 1st picture.

the 2nd picture is the hall sensor wires for the controller. I assume Red & Black are for power and the Yellow, Green, Blue wire correspond to the same color wire as the phase wires.

so the question is which Hall sensor wires on the transmag controller correspond to the same wire on the new controller?

thanks

 

[fechter]

Inside the Kollmorgen motor, you'll notice BYG markings (Blue Yellow Green) These should match to the blue yellow and green wires on the controller. The hall senor wires are blue yellow green also, so they should correspond. The black and red wires are the ground and +hall power.

On the Kollmorgen, I can't remember the hall configuration, I have a Kollmorgen sitting outside, I will check the hall wire colors tomorrow.
The little board with the hall sensors is marked as I remember.

The idea is each hall sensor corresponds to a phase on the controller.


There's only so many possible combinations. A wrong combination can blow the controller.
I highly recommend testing with a current limited power supply until you verify the thing can run at full speed and only draw about 3 amps. You could use a 5 amp fuse if you don't have any other way to power it.

Test with the motor unloaded (wheel in the air or no chain).

Alternately, it's real handy to measure the current when you test. If you have a bad combination, the current will be excessively high or it just won't run (or both).

With a bench power supply, you can hook them up wrong without much risk of damage.

If it runs backwards, you swap any pair of phase wires and the corresponding hall wires to reverse it.

 

[fechter]

Here's a pic of the backside of the hall board. White= +hall power, black= ground.

So,
(K= Kollmorgen):
K white to red
K black to black

I would guess:
K green to yellow
K orange to blue
K red to green

 

[tno]

the transmag controller was connected this way:

K (hall) green to green K (motor)
K (hall) orange to yellow K (motor)
K (hall) red to blue K (motor)

i'll try this 1st with a fuse.

thanks for the info.

 

[tno]

by the way, do you think the new controller in the picture above can be modified to work with 72v?

the controller was taken out of a panterra fusion 48v scooter. it's rated for 48v 25amp.

it has 12 STP75nf75 mosfets
3 IR2103 drivers
a 63v 2200uf capacitor

there appears to be a separate turn on (+) lead. So I was thinking that the capacitor and mosfets can be swapped out for higher voltage ones. Then connect 48v to the turn on lead and 72v to the main power lead.

 

[knoxie]

Hi

Yes I think that Fechter has been spot on with his advice, limit the controller supply and go very gentle with the throttle when testing, if nothing happens dont open the throttle more.

Those Fets can not be run at 72V they will blow, you can drop in the 4310 as Bob mentions in this thread you can run it at 72V, not sure how they limit the current on the controller however you would still get 25A at 72V which should be enough for you?

Check the board capacitors the bootstrap caps and see what voltage they are as you may have to up those, also not sure if this controller has a regulated board supply? may want to check the voltage regulator.

Good luck!!

If all else fails get a blown controller like the ones in this thread and have a go at fixing one!! Tim Brown at powerpack motors may have a bad controller he is prepared to sell you, you can of course buy a new controller from Tim.

Cheers

Knoxie

 

[fechter]

the transmag controller was connected this way:

K (hall) green to green K (motor)
K (hall) orange to yellow K (motor)
K (hall) red to blue K (motor)

i'll try this 1st with a fuse.

thanks for the info.

I think you're right. If you look at the pic of the hall board on the Kollmorgen, you'll see the signal wires are marked SA, SB, SC

On your controller, the phase wires are marked A, B, and C. I think you should try to match up the phases as marked. The only thing I'm not sure about is which wire coming out of the motor corresponds to which phase.

There might be markings on the Transmag controller that would tell you.

With 75v rated FETs, your maximum battery voltage should be under 60v.
The main capacitor looks undersized. If there's any way to stuff two or more in parallel, it would help, even if extended by wires. If you want to run 72v, the main cap and FETs should be rated for 100v.

I see the shunt on your controller. It's the pair of short jumpers near where the main battery neg. wire attaches. If you add another jumper in parallel, it will boost the current limit. I would keep it stock for now, I don't think a Kollmorgen motor can handle a lot more than 25 amps.

 

[bobmcree]

i routinely run my Kollmorgen/USPD at 35-40A @48v and it does not have a problem. one must remember that the 35-40A is the input current to the controller and not the motor current. 72v@35A will put a lot more current through the windings than 48v@35A.