PWM Kit received for the Tyco Kilovac EV200A1ANA

Look what came in the mail yesterday :-)

A small PWM kit I ordered few days ago to replace the resistor & capacitor used as an economizer for the Tyco Kilovac EV200A1ANA that requires one

This resistor & capacitor have been doing the job, except that the resistor is burning some energy in heat  and this is maybe no the best way to handle this problem

Now, I just have to switch on my soldering iron and put all this components together on the PCB ...

Link to this item: http://boutique.rhaaa.fr/49-kit-r%C3%A9gulateur-pwm.html

ESS - Kilovac mounted on Control Board & first test

Now the EV200A1ANA is screwed on the Control Board and wired to the charger side command relay

First test on video

The resistor and capacitor are not soldered yet because I am not sure of the best location

I positionned them next to the other Kilovac EV200AAANA, because there is a hole on top of it - toscreww battery cables - and the heat generated by the 10W resistor will be able to get out of the enclosure  through it

The 6 chargers leads will be connected this week end

Low Cost Coil Economyzer Test for Tyco Kilovac EV200A1ANA

I am still in search of an economizer for my new Tyco Kilovac EV200A1ANA

Last night, I tested different resistor values along with this 4700uF capacitor - I got for my Grid Tie Inverter repair previously - and found that the simple economizer described in this DIY Electric Car thread


seems to work . I could not find a resistor that works so I used this air dryer resistive wire again - alreday used on my mini bottom balancer - and cut a piece that was 10Ohms;

Closing the circuit bypassing the economizer, the relay closes and is using 3,5A

With the economizer, the contactor is closing and only 1A is going through the circuit - instead of 3,5A with no economizer -   

1A at 12V = 12W

I will have to try with 20Ohms and see if what it does ... The idea is to leave the relay closed using minimum current, thus minimum power

Testing Tyco Kilovac EV200A1ANA coil with 12V Battery

So this new Tyco Kilovac EV200A1ANA contactor requires an economizer to avoid coil overheating and getting damaged

Talking a lot on the phone and by mail about it with my dad, he told me to see if the coil was realy overheating and that is what I did using a small 12V AGM battery as a 12V source and also wired an ampmeter - in series - to see the current going in 

3,5A showing here and 3A after few minutes

Not showing on this picture but the temperature went up to 30°C when I left the power - 12V @ 3,5A - on the coil leads for more than 5 minutes, so it is getting warm and consuming some power - 36W or more -

I am still reading einteresting stuff online to make a simple economizer with a simple resistor and a capacitor ,in parallel, wired in series with the coil : http://www.diyelectriccar.com/forums/showthread.php/evdl-coil-economizer-13711.html 

Opening up the Tyco Kilovac EV200AAANA Economizer box

Saturday morning I decided to open up the Economizer box attached to the Tyco Kilovac EV200AAANA to see what this PWM circuit is made of; So I started by unscrewing the voltmeter and then the contactor
from the control board after taking the battery cables off its terminals


After that it was easy to remove this side box/cover

voilà

and here is the Tyco Economizer: it is actuelly a small PCB with 3307 reference number printed on it: KILOVAC 3-70-3209

and there are quite a few components soldered onto it !