brucedp5 via EV wrote:
my S-10 Blazer conversion... arrived as a 120VDC T125 system using a
Curtis 1221x controller to power the 9" ADC dual-shaft e-motor... the
first curtis died...
openings in that potting material... outside air would breath in moisture...
would cause corrosion, which would lead to eventual internal component failure.
So, anyone doing a curtis repair, ensure the controller is back in a
sealed, air tight environment again (make sure the unit has no way
for moisture to get in).
Right! The hard potting does not stick well to the aluminum case. Often,
the end with no terminals will simply fall out. The end with the
terminals can't fall out (the terminals still hold it in position), but
there will be a crack all the way around between it and the case.
After repair, I reseal them with silicone rubber. It is soft, adheres
well to the case, and is easy to cut (the NEXT time it fails).
Heat: The life of any electronic device is roughly *halved* by every 10
deg.C rise in temperature. That's why it's important to do whatever you
can to cool it. If you can't comfortably leave your hand on it after a
drive, it's too hot! Find some way to cool it better.
Don't get me wrong: The Curtis is not a bad design. In fact, it's better
than most. The problem is that an EV controller leads a very hard life.
Shock, vibration, heat, cold, water, dirt, very high current surges,
voltage spikes, and time will eventually do it in.
Also, another item causing failures was having proper cooling.
Typically, the controller was mounted on a heat sink for low power
use. But in the higher (144V) use, the best cooling even on hot
days, was to have the controller mounted on a large heat sink, with
12V fans mounted on the top and bottom (like a sandwich) to ensure
the controller had enough cooling.
--
Teaching children to program goes against the grain of modern education.
Just imagine the chaos if they learned to think logically, plan, create,
implement, test, and execute!
--
Lee Hart, 814 8th Ave N, Sartell MN 56377, www.sunrise-ev.com
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