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Re: Removing stock controller and using my own.

Posted: Mon Mar 27, 2017 9:14 pm
by VitaminJ
powersurge wrote:You know, you are absolutely right. I think the 400 volts of electricity the leaf packs makes taking the motor apart to tinker with is a dangerous thing. I am a naysayer in numerous other areas also...

I am against taking a new leaf's whole dashboard apart to install a cool stereo. I am against guys spending $300 for a new marine battery that only runs the headlights and accessories. I also am against people being given the idea to spend hundreds per tire to make the leaf drive like a corvette (which will not happen). I don't need to go on.....

So... Just like any guy has the right to talk about taking the Leaf apart to count how many pieces he has, I have the right to say when I have an opinion. It's called acceptance, and freedom of speech. If you can't handle that, I know where you can plug your j1772 plug... Peace...

Wow must have touched a nerve. You are indeed against a lot of things. It's funny how much you urge others to stick to convention and yet you drive an electric car :mrgreen:

Re: Removing stock controller and using my own.

Posted: Thu Mar 30, 2017 11:31 am
by powersurge
VitaminJ wrote:
powersurge wrote:You know, you are absolutely right. I think the 400 volts of electricity the leaf packs makes taking the motor apart to tinker with is a dangerous thing. I am a naysayer in numerous other areas also...

I am against taking a new leaf's whole dashboard apart to install a cool stereo. I am against guys spending $300 for a new marine battery that only runs the headlights and accessories. I also am against people being given the idea to spend hundreds per tire to make the leaf drive like a corvette (which will not happen). I don't need to go on.....

So... Just like any guy has the right to talk about taking the Leaf apart to count how many pieces he has, I have the right to say when I have an opinion. It's called acceptance, and freedom of speech. If you can't handle that, I know where you can plug your j1772 plug... Peace...

Wow must have touched a nerve. You are indeed against a lot of things. It's funny how much you urge others to stick to convention and yet you drive an electric car :mrgreen:


The only nerve that is touched, my friend, is you. You have to be "touched" to continue with your teenage game of "got you last" with this topic. I hope that the site administrator catches your ridiculous posts and puts some restrictions on your account. But thanks for showing all of the readers of this site who you really are...

Re: Removing stock controller and using my own.

Posted: Tue Apr 04, 2017 9:58 pm
by MPaulHolmes
I'll be sure to post any progress w.r.t. replacing the controller. Tomorrow I go to get the title changed from salvage to "not salvage anymore", whatever they call it. It was a $60 fix, and the insurance company totalled out the car. haha. Well, I didn't paint the new panel yet, so maybe a $61 fix after I let my 5 year old paint that spot.

Re: Removing stock controller and using my own.

Posted: Wed Apr 05, 2017 8:58 am
by VitaminJ
Back to your original question, I'm almost more interested in learning how to adjust/tune/tweak the stock controller vs. using an aftermarket one. I've been following you on youtube before I realized you also posted here so I'll keep on watching to see how it goes.

Re: Removing stock controller and using my own.

Posted: Tue Apr 18, 2017 4:45 am
by Marktm
MPaulHolmes wrote:I'll be sure to post any progress w.r.t. replacing the controller. Tomorrow I go to get the title changed from salvage to "not salvage anymore", whatever they call it. It was a $60 fix, and the insurance company totalled out the car. haha. Well, I didn't paint the new panel yet, so maybe a $61 fix after I let my 5 year old paint that spot.


Paul - post some pictures of before and after - will be interesting to see how you brought a Leaf back from a junk yard death!!

Re: Removing stock controller and using my own.

Posted: Thu Apr 20, 2017 11:51 am
by chaz
VitaminJ wrote:Back to your original question, I'm almost more interested in learning how to adjust/tune/tweak the stock controller vs. using an aftermarket one. I've been following you on youtube before I realized you also posted here so I'll keep on watching to see how it goes.


You could try what I want to try but have not gotten to yet...
Replace the motor phase current sensors with a higher current version and trick the controller to think the car is only providing half the power to the motor. The service manual states there is an error state if the IGBTs heat up due to over current but who knows if it would work, they are very well heatsinked. Worst case you blow an IGBT then you swab the IGBTs out for higher current versions. The battery current sensor may also have some concerns if you start drawing 300+ amps from the battery, but that could get swapped out also.

If anyone has info on the IGBT MFG part # and the current sensor MFG part # i would love to start looking into replacements.

Last note here: this is the ENGINEERING section of the forum, if you are not a competent Engineer or skilled trades person who understands the risk/reward of doing testing like this, DO NOT ATTEMPT IT. Lay off Paul, he has been a good inspiration to many with his work.

Re: Removing stock controller and using my own.

Posted: Tue Oct 10, 2017 7:26 am
by RNM
chaz wrote:Replace the motor phase current sensors with a higher current version and trick the controller to think the car is only providing half the power to the motor. The service manual states there is an error state if the IGBTs heat up due to over current but who knows if it would work, they are very well heatsinked. Worst case you blow an IGBT then you swab the IGBTs out for higher current versions. The battery current sensor may also have some concerns if you start drawing 300+ amps from the battery, but that could get swapped out also.

If anyone has info on the IGBT MFG part # and the current sensor MFG part # i would love to start looking into replacements.

Would love to know if this works

Re: Removing stock controller and using my own.

Posted: Sun Oct 15, 2017 11:34 am
by arnis
One can not unckeck "voltage drop".
Drove Leaf today at full speed. There is not a lot of reserves.
AFAIK, 24kWh battery is capable supplying 85kW of power.
Though I lost one power bubble during max speed.
Power electronics heated up from 40C to 60C within half a minute.
It was cold outside, 8C.

Leaf is not going to do a lot more without limitations.
Want more acceleration, decrease tire circumference ;)

Re: Removing stock controller and using my own.

Posted: Sun Oct 15, 2017 12:32 pm
by RNM
arnis wrote:
Power electronics heated up from 40C to 60C within half a minute.


How did you measure it?

Re: Removing stock controller and using my own.

Posted: Mon Oct 16, 2017 12:49 am
by arnis
LeafSpy shows now (newest version).