Search found 40 matches

by Ribfeast
Mon, 03 Jun 2019, 13:52
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 471
Views: 32685

Re: Prelude conversion project - some questions

Looks great! Crazy how tiny those motors are compared to the gearbox!
by Ribfeast
Thu, 16 May 2019, 06:41
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

The controller seems to have recalibrated itself and now drives the same as the old one. Must be some pretty clever electrickery going on inside.
by Ribfeast
Wed, 15 May 2019, 06:31
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Installed the controller in the kart last night finally, great to have it up and running again! Had to adjust the accelerator stop button to eliminate a 2-flashes issue. For some reason this new controller appears to draw a bit more current than the old one, so maybe it has some different motor para...
by Ribfeast
Mon, 13 May 2019, 07:42
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Yes contactor clicks on, and resistance between the outputs drops to zero.
Was interstate for the weekend so will fit it one night this week.
by Ribfeast
Fri, 10 May 2019, 10:52
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

New controller has arrived at work, can't wait to get home and fit it! It's a generic one with the same model number, hopefully there is no Toro-specific programming in the old one.
by Ribfeast
Wed, 01 May 2019, 18:26
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Just rechecked, only getting 1 volt between Pin 8 (contactor) on the Controller, and the 12V switched pole. The controller is supposed to drop pin 8 to ground when ready, and it doesn't seem to be doing this, it just floats up to positive voltage. Tried fooling it with a resistor but no luck. Going ...
by Ribfeast
Wed, 01 May 2019, 11:16
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Cheers I'll give it a go ::) It's black and quite hard. When I hit it with the heat gun it gets a bit crumbly. Going to check the contactor coil resistance tonight, and the condition of the motor brushes before digging into the controller further. Would be nice if there was a way to bench test the u...
by Ribfeast
Wed, 01 May 2019, 06:26
Forum: Electric motors and controllers
Topic: Faulty Sevcon controller
Replies: 0
Views: 286

Faulty Sevcon controller

My girlfriend parked up the Toro Workman MDE 48V kart yesterday and then went to use it later in the afternoon, it makes all the right noises (reverse beep etc) but the main contactor doesn't click on, and getting 4 flashes on the dash. Tried bridging the 2 large terminals on the contactor to allow ...
by Ribfeast
Wed, 01 May 2019, 06:26
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

My girlfriend parked up the Toro Workman MDE 48V kart yesterday and then went to use it later in the afternoon, it makes all the right noises (reverse beep etc) but the main contactor doesn't click on, and getting 4 flashes on the dash. Tried bridging the 2 large terminals on the contactor to allow ...
by Ribfeast
Fri, 12 Apr 2019, 12:33
Forum: Technical and conversion discussion
Topic: Hot rod EV - looking for advice.
Replies: 41
Views: 2252

Re: Hot rod EV - looking for advice.

That video makes me really want to build one of those now!
by Ribfeast
Wed, 03 Apr 2019, 11:19
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Finally mounted up the inverter, here's a quick video of the BMS and inverter doing their thing, with the air compressor running off it.

https://imgur.com/a/Kux2ZZB
by Ribfeast
Fri, 15 Mar 2019, 12:05
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

I've picked up a 2000W pure sine 48V inverter (4000W peak), it appears to run my compressor, power tools, heat gun and other items easily, problem is it is so big I can't mount it anywhere on the kart! Will cut a suitable place for it over the weekend. But it could run the 650W server rack, or a fri...
by Ribfeast
Fri, 15 Mar 2019, 08:40
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Aaaargh! That would have been perfect! And saved me a few grand! :(
by Ribfeast
Thu, 07 Mar 2019, 07:37
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

If you lived a bit closer you'd be welcome to try, I should try it on our 1500kg horse float sometime actually.
by Ribfeast
Wed, 06 Mar 2019, 07:56
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Forklift is probably better rated lol

Toro Workman MDE is rated for 363kg towing, about 10% of what you want. On flat ground I'm sure it would do it, but doubt it would be good for it.

http://www.toro.com.au/media/4094/200-4 ... X-MD-D.pdf
by Ribfeast
Wed, 06 Mar 2019, 05:31
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Farm Machinery Sales (.com.au) had a few when I looked recently, cheapest was still around $8k or so though. TradeFarmMachinery has some too: https://www.tradefarmmachinery.com.au/detail/toro-workman-653170 These are also something I considered at the time: http://pickman.com.au/listings/pickman-kw4...
by Ribfeast
Tue, 05 Mar 2019, 05:17
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

It probably could, I know the brakes on mine wouldn't be up to stopping it on any kind of slope though. It would need to have a towball fitted etc, and would definitely be well outside the rated towing capacity. But if it is just on level ground I reckon it would be fine. I've put a tow hitch on our...
by Ribfeast
Mon, 04 Mar 2019, 06:35
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Some pictures :) https://imgur.com/a/pH8l9tN Just need to do a few tweaks to the voltage limits for charging etc, currently it is set a bit conservative. I'd also like to upgrade the white battery monitoring wires to thicker ones so that the current shunting works better, I think they are a bit thin...
by Ribfeast
Sat, 02 Mar 2019, 09:33
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Wired it all up yesterday with BMS etc and took it for a spin, runs like an absolute animal now, goes up hills like they aren't there, seems to peak at around 185A draw with just me in it on a moderate 30 degree hill. Drove it to a mate's place and we took it up a 45 degree hill together and hit 300...
by Ribfeast
Thu, 28 Feb 2019, 06:48
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Power supply has arrived and I have been performing a balance charge for the last few days. Have the power supply set at 3.45V and it has been hovering at around 8-10A output without dropping (bank is wired as parallel, ie 1600Ah). Pack is sitting around 3.35V. Around 1.7kwh has been sent to the pac...
by Ribfeast
Mon, 25 Feb 2019, 05:57
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Battery box built :) https://imgur.com/a/IlTpuF9 Have configured as 4S4P temporarily and attached to a gel charger for a few days while I wait for the variable power supply to arrive. It's just hit the country so hopefully I'll see it soon. Will then reconfigure to 16P and finalize the balance charge.
by Ribfeast
Wed, 20 Feb 2019, 05:45
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Batteries have arrived, I've made up a temp bus bar out of some aluminium flat bar for the initial balance charge. 3.2V 1600Ah, wouldn't want to drop a screwdriver on it!

https://imgur.com/a/6o6j5A8

Just waiting on BMS and charger. Charger might be a few weeks :(
by Ribfeast
Fri, 15 Feb 2019, 13:03
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

Ah if the controller has HV protection then it should be OK. Have to check if the Zeva BMS has similar protection. Thanks Richo :)
by Ribfeast
Fri, 15 Feb 2019, 07:08
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

If the pack were to disconnect due to a low voltage shutdown, would a TVS diode like the one below be suitable to absorb the HV spike generated by the motor when its power is cut? Just trying to protect the Sevcon in case someone ever ran the battery too low and it shut off, or if regen braking exce...
by Ribfeast
Thu, 14 Feb 2019, 13:02
Forum: Technical and conversion discussion
Topic: Lead acid to lithium conversion
Replies: 65
Views: 3986

Re: Lead acid to lithium conversion

OK order has been placed for 16 LiFePO4 cells, Zeva BMS, safety contactor, monitor screen for BMS, temp sensor, cell interlinks. Just need to obtain a bench power supply to provide the initial 3.65V balance charge. Other things to get will be a flyback diode for the contactor to protect from HV spik...