Downloadable
files
WORD documents
Reg bus instructions in WORD format (35 kB).
Single sheet regulator instructions in WORD format (31
kB)
Mark 2 Regulator and Regbus concept document
in WORD format (77 kB)
PFC20 installation in WORD format (29 kB)
PFC20 installation REV B in WORD format (23 kB) Figure 1 Figure 2 Figure 3 Figure 4 Figure 5
PFC20 installation REV C in WORD format (32 kB) Figure 1 Figure 2 Figure 3 Figure 4 Figure 5
PFC20 installation REV C in Text format (10 kB) Figure 1 Figure 2 Figure 3 Figure 4 Figure 5
Application note #1: Running Manzanita Micro PFC chargers on Generators (1878 kB)
Short Instructions REV 2B in WORD format (20k)
PDF documents
Short Instructions REV 2B in PDF format (22k)
Text documents
Interface connector pinout TEXT document (3 kB)
Remote control Questions and Answers TEXT document (7 kB)
Schematics
Remote control page 1 (76kB) March 21 2002 Contains errors documented
in Remote Control Q&A above
Remote control page 2 (66kB) March 21 2002
Remote control page 3 (76kB) March 21 2002 Contains errors documented in
Remote Control Q&A above
Battery Blaster (9 kB GIF) 27 June 2002 This is the device that we use to measure
the drag race batteries.
Charge voltage limiter for Bad boy chargers (25kB KDF) (it was too big for me to make
into a GIF in a reasonable period of time so I used the Kinko's file prep tool available from Kinko's)
Battery cycler schematic (21kB GIF image) This is the schematic of the PC based battery cycler. The battery connects to the battery terminals, the charger to the charger terminals, the load to the load terminals and the PC to the DB-9 and DB-25. The 15 volt power supply needs to supply enough current to activate the contactors without glitching the emeter brain.
REGBUS interface (11kB GIF image). This is the input from the REGBUS into the charger controller board.
Photos
Monster Charger load at 20 kW(416 kB JPEG photo)
Monster Charger front panel at 20 kW(374 kB JPEG photo)
Mk 2 Regulators and PFC-20 in back of Goldie (93 kB JPEG photo)
PFC50 power stage (160 kB JPEG photo)
Windloader 100 hairball (308 kB JPEG photo)
PFC-20 overheated fuse (83kB photo)
Project 8 advanced (69k photo)
Project 8 retard (67k photo)
Project 8 Brush end view (595k photo)
Project 8 12 turn case (47k photo)
Project 8 Stock 37 bar commutator (47k photo)
Mk 2 regulator with regbus board (614k photo)
Mk 3 regulator preliminary (617k photo)
Mk 3 with communication wedge (594k photo)
First revision 2 charger Front view
(~769k photo)
Craftsman genset waveform
that killed a PFC-20 (15k gif image) This was recorded from a 2:1 step
down transformer. The 240 VAC outlet is twice this voltage.
Photo of a virgin brush out of a AC4-4002 Close up (30k jpeg) and further
away (38k jpeg).
Fresh brush from AdvDC. Notice 80% swept area (188k jpeg).
Radiused Brush with sandpaper on commutator (201k jpeg).
Gone Postal new 9 inch motor during brush break in (226k jpeg).
Dyno and both Gone Postal 9 inch motors. Blue is GE. Black in AdvDC. Both motors on dyno frame are 8 inch AdvDC (213k jpeg)
Brush after break in (178k jpeg).
Sbeam load cell (208k jpeg)
Drag Race Battery test data
These files are tests of batteries that are candidates for drag racing. As we get our hands on more of them, they
will be posted here. The best way to view these is to right click on the link and press "download target".When
the download finishes, press the "open file" button.
The old genesis battery is a 38 amp hour unit that only runs 28 minutes on a reserve capacity test. This battery
was removed from a car in 2001 and sat unused on a cement floor for over 12 months before being put into service
for testing this tester. It still kicks some serious amps for weighing only 33 pounds.
Old Genesis (549 kB Excel file) A retired battery
used to develop the process. There are annotations on the graphs explaining some of the features of the plots.
SVR #4 (490 kB Excel file) This is an early file while I was experimenting with data formatting.
SVR #5 (522 kB Excel file) This is an early file while I was experimenting with data formatting.
SVR04 and genesis (1097 kB Excel file) 900 amp
test showing the differences in power with changes in temperature. The Genesis does not reach full power during
this test.
SVR battery tests (1587 kB Excel file) eleven test discharges showing how much power
each of eight SVR batteries will make. This test was used to check that they are within a few percent of each other.
Two of the SVR batteries were kept in an oven for three days prior to do elevated temperature tests. The old Genesis
test was run to verify the current sensor was not clipping.
Optima battery tests (709 kB Excel file) >1000 amp tests showing the differences
in power with changes in temperature. The current sensor was malfunctioning at 1000 to 1100 amps in the first three
of the five tests. Time limits prevented more cycles. Note that the power availability increases with temperature.
Also note the fourth test is the slope down from peak current. Part of the file was accidentally overwritten before
download.
25 cycles on Yellowtop #19 (1455 kB Excel file) shows the effect cycling
has on a three year old yellowtop that was sitting negelected on the garage floor for two years. The environment
was a cold shed that got up to into the 60's during the day and dropped to the 30's at night. I ran 13 cycles with
a theshold of 14.5 to go into the two amp overcharge. On the 14th cycle I noticed the battery would not go into
equalization phase so I reduced the acceptance voltage to 14.1 so the voltage would hop up. The battery stopped
growing in capacity when I did this. Note that the discharges are run at 25 amps to imitate a reserve capacity
test.
SAFT100 tests (351 kB Excel file) Shows that the pair of 6 volt batteries is capable
of soucing 6000 watts at 1000 amps. Pulling more current than this will reduce the power delivered. The test indicates
the pair of batteries has a 6 milliohm impedence. Test was run one month after being charged and at 75F.
SVR30 tests (1.7 MB Excel file) This battery got quite warm after five tests. It was hot to the touch but not too hot to hold. I would estimate it as 110F. The fourth test had a spark at one terminal that left lead splatter on top of the battery and welded the lug to the terminal. I loosened the bolt and twisted the cable to get it off. Peak power observed was 8000 Watts.
Small Optima Red Top tests (1.47 MB Excel file) This battery came up to temperature in four tests and I ran out of time to do the fifth test. It was about 90F at the end of the fourth test. Peak power observed was 10.2 kW.
Exide Orbital tests (18 August 2003)
Test 1 624 amps 88F
Test 2 1488 amps 92F
Test 3 1440 amps 95F
Test 4 1744 amps 101F (Pesky breaker opened near peak amps)
Test 5 660 amps No temp (found out data is reading 16% high)
Test 6 720 amps 112F
Test 7 1800 amps No temp
Test 8 1800 amps 132F
Test 9 2000 amps No temp
Test 10 2100 amps 120 F
Evercel cycling data
Evercel cycling report 1 (412 kB Excel file) This 7 cell battery was delivered
with a bad cell. It was considered a corpse. We put it on the cycler to see what it would do. The first few cycles
the battery was sleeping. We almost got a thermal runaway on Charge 6. We did get a thermal runaway on cycle 9.
The thermal runaway only got up to 90F in a 47F environment. The bad cell shows up in the data during charges 7,8
& 9 and discharges 7,8 & 9. Cycling will continue until we get consistent results.
Evercel cycling report 2 (758 kB Excel file) This is the same 7 cell battery but includes data for cycles 10 through 16. The battery is starting to act consistent from cycle to cycle. Energy output is stabilizing at about 500 watt hours per cycle.
Evercel cycling report 3 (1767 kB Excel file) This is the same 7 cell battery but includes data through cycle 30. Energy output has been as good as 882 watt hours. Energy per cycle is not consistent. Some cycles are higher than others. The bad cell characteristic seems to have disappeared on the later cycles.
Evercel cycling report 4 (2971 kB Excel file) This is the same 7 cell battery but includes data through cycle 42. Energy per cycle is becoming more consistent. Energy output was 971 watt hours on cycle 41. Ampere hour output was 83.2 on cycle 41. This is not bad considering that this battery puked out about a cup of electrolyte on its commissioning charge before I got it.
Evercel summary for cycle 102 (23 kB gif image) The battery capacity has dropped under 80 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel summary for cycle 149 (26 kB gif image) The battery capacity has dropped under 73 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel summary for cycle 200 (29 kB gif image) The battery capacity has dropped under 70 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel summary for cycle 254 (15 kB gif image) The same battery has dropped to 63.3 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel summary for cycle 309 (16 kB gif image) The same battery has dropped to 61.6 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel summary for cycle 352 (16 kB gif image) The same battery has dropped to 56.2 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel summary for cycle 404 (16 kB gif image) The same battery has dropped to 52 ahr. A tendency to have low capacity if left sitting for a while after charging and before discharging is apparent.
Evercel thermal behavior (16 kB gif image) The evercel warms up during discharge and during overcharge and cools off during charge. The temperature swing was from 75F to 90F in a 39F ambient.
MB100 at 45 cycles (14 kB gif image) This is an eight cell MB100 with a plastic case. It was not a reject (as the M100 turned out.) The initiation went much faster. It was making full capacity on the sixth cycle. From what we learned on this battery, we think we can get them up to full capacity even faster. Stand by for more results.
MB100 at 125 cycles (20 kB gif image) This is an eight cell MB100 with a plastic case. It was not a reject (as the M100 turned out.) This battery sat from July to November 2003 and the performance degraded during the off time. The person who supplied the battery recommended that I stop cycling it because the entire lot is not working correctly. I noticed that the capacity is unstable in the latter tests. It sometimes puts out more ampere hours than were put into it on the last cycle. For instance, I would recharge it with a fixed 60 AHR on sequences 175 to 185 but the discharges would alternately produce 60 and 40 AHR. I believe this is due to a low discharge voltage triggering an early end of discharge. The following charge seems to indicate that it was full about 8 to 10 AHR after the capacity was returned. I was running a fixed recharge capacity with my NiCad program so it did not terminate when the battery was full. It put in the programmed AHR. By watching the peak on the previous cycle, I could judge the necessary AHR to refill it on the next cycle.
MB80 at 34 cycles (15 kB gif image) This is an eight cell MB80 with a metal case. It was not a reject (as the M100 turned out.) This battery sat from July to December 2003 while the power to the shop was inadequate to support testing. Note that the capacity came up to its maximum on the seventh cycle and the degradation is fairly slow. Unlike the MB100, the MB80 needs about 20 Ampere hours of overcharge to make full capacity.
MB80 at 54 cycles (16 kB gif image) This is an eight cell MB80 with a metal case. It was not a reject (as the M100 turned out.) This battery sat from July to December 2003 while the power to the shop was inadequate to support testing. Note that the capacity started dropping at cycle 40.
MB80 at 70 cycles (30 kB gif image) This is an eight cell MB80 with a metal case. It was not a reject (as the M100 turned out.) This battery sat from July to December 2003 while the power to the shop was inadequate to support testing. Note that the capacity started dropping at cycle 40 and recovered back up to the mid 60's after the cold spell as indicated by the temperature chart inset that is synchronized with the cycle data..
MB80 at 196 cycles (27 kB gif image)MB80 at 166 cycles (27 kB gif image)MB80 at 123 cycles (27 kB gif image) MB80 at 84 cycles (22 kB gif image) This is an eight cell MB80 with a metal case. It was not a reject (as the M100 turned out.) This battery sat from July to December 2003 while the power to the shop was inadequate to support testing. Note that the capacity started dropping at cycle 40 and recovered back up to 65 AHr.
This page last edited on 12 September 2005 by Joe Smalley
