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--- astra_conv:conversion:cooling_system:cooling_system [2014/03/20 17:01]
richard created
+++ astra_conv:conversion:cooling_system:cooling_system [2014/04/23 18:09]
richard [liquid coolant circuit]
@@ Line 3: / Line 3: @@
 ====== cooling system  ======
-As mentioned before, the motor is foreseen for watercooling, but this is not required in any case. Watercooling should rather be regarded as "optional" to prevent that the controller throttles down the motor at persistently high load, especially in hot weather.
+As mentioned before, the motor is fitted for liquid cooling. Although it can even be operated "dry", cooling  prevents that the controller throttles down the motor at persistently high load, especially in hot weather.
-Besides the coolant ducts of the motor itself, the water cooling circuit consists of a small cooler from a Honda 250 scooter and a circulation pump. Together with the heater circuit (which has its own circulation pump), the cooling circuit is connected to the original coolant liquid reservoir. The air buffer in the reservoir can be pressurized to ease refilling and emptying of the two circuits.
+In contrast to the motor, the controller is air cooled. It also tends to overheat under harsh conditions, so the cooling system includes forced air cooling of the controller. The cooler fan of the air conditioning system is reused for this purpose.
-The cooler got a place near the front grille, at the passenger side. From it's scooter past, it already has a small fan attached.
-{{:astra_conv:conversion:motor_cooler:p1110310.jpg?770|}}
-DIY bleeder screw at the top of the cooler:
-{{:astra_conv:conversion:motor_cooler:p1110255.jpg?340|}} {{:astra_conv:conversion:motor_cooler:p1110256.jpg?340|}}
-In addition to cooling the motor, I have also employed the cooler fan of the air condition system, for forced cooling of the motor controller.
 The fans and the coolant pump are independently controlled, depending on the temperature of motor respectively motor controller.
-Currently, the components of the cooling system are prepared, but not yet installed.
@@ Line 64: / Line 52: @@
 {{:astra_conv:conversion:motor_cooler:p1110277.jpg?500|}}
+Temperature sensors - The double sensor is glued to the motor, one of the NTCs is for the cooler controller itself, the output of the other one is relayed to the temperature gauge in the dashboard (as long as the coolant heater is off).
+The NTC sensor for the motor controller is fitted into a cable shoe and bolted to the motor controller's heat sink.
+{{:astra_conv:conversion:motor_cooler:p1110717.jpg?340|}} {{:astra_conv:conversion:motor_cooler:p1110879.jpg?340|}}
 \\
@@ Line 101: / Line 98: @@
 {{:astra_conv:conversion:motor_cooler:lowest.jpg?225|}}{{:astra_conv:conversion:motor_cooler:low.jpg?225|}}{{:astra_conv:conversion:motor_cooler:highest.jpg?225|}}
-It turned out that both fans can be controlled well via PWM signal. However, both emit quite some audible noise at pulsed operation.
+It turned out that both fans can be controlled well via PWM signal. However, both do emit quite some audible noise at pulsed operation.
+\\
+===== liquid coolant circuit =====
+The coolant liquid is circulated by an electric pump, through the motor and though a small radiator. Together with the heater circuit (which runs independently and has its own circulation pump), the cooling circuit is connected to the original coolant liquid reservoir. The air buffer in the reservoir will take up thermal expansion of the coolant liquid, and it can be pressurized to ease refilling and emptying of the two circuits.
+The cooler got a place near the front grille, at the passenger side. From it's scooter past, it already has a small fan attached.
+{{:astra_conv:conversion:motor_cooler:p1110310.jpg?770|}}
+DIY bleeder screw at the top of the cooler:
+{{:astra_conv:conversion:motor_cooler:p1110255.jpg?340|}} {{:astra_conv:conversion:motor_cooler:p1110256.jpg?340|}}
+Coolant terminals on the motor (picture is borrowed from the "drivetrain" section).
+{{:astra_conv:conversion:drivetrain:p1100856.jpg?300|}}

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