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Discussion Starter #1
I drove my Yaris on the Freeway today and never pulled more than 60
battery amps, the engine light would blink every once and a while
after the first 5 miles or so. I have the Ev source cooling kit and a
fan blowing on the radiator. Is this a temp warning? It's less than
70 outside and I thought I had the controller over cooled. It has
also blinked in the evening when it is under 60 outside and using the
controller harder.


Thanks,

Mark

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Discussion Starter #2
That's the reply I got - of course it's over 100 here, and it typically flashes towards the end of the hot afternoon drive, so I can believe it's getting hot. It's hard to believe yours is...





David Brandt


----- Original Message ----
From: Mark Dutko <[email protected]>
To: [email protected]
Sent: Sunday, August 19, 2007 8:26:56 PM
Subject: [EVDL] Zilla Engine Light Blinking


I drove my Yaris on the Freeway today and never pulled more than 60
battery amps, the engine light would blink every once and a while
after the first 5 miles or so. I have the Ev source cooling kit and a
fan blowing on the radiator. Is this a temp warning? It's less than
70 outside and I thought I had the controller over cooled. It has
also blinked in the evening when it is under 60 outside and using the
controller harder.


Thanks,

Mark

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Discussion Starter #3
That's what I was thinking- It should be over cooled I would think???

Mark
David Brandt wrote:

> That's the reply I got - of course it's over 100 here, and it
> typically flashes towards the end of the hot afternoon drive, so I
> can believe it's getting hot. It's hard to believe yours is...
>
>
>
>
>
> David Brandt
>
>
> ----- Original Message ----
> From: Mark Dutko <[email protected]>
> To: [email protected]
> Sent: Sunday, August 19, 2007 8:26:56 PM
> Subject: [EVDL] Zilla Engine Light Blinking
>
>
> I drove my Yaris on the Freeway today and never pulled more than 60
> battery amps, the engine light would blink every once and a while
> after the first 5 miles or so. I have the Ev source cooling kit and a
> fan blowing on the radiator. Is this a temp warning? It's less than
> 70 outside and I thought I had the controller over cooled. It has
> also blinked in the evening when it is under 60 outside and using the
> controller harder.
>
>
> Thanks,
>
> Mark
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
>
>
> ______________________________________________________________________
> ______________
> Yahoo! oneSearch: Finally, mobile search
> that gives answers, not web links.
> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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Discussion Starter #4
If it's air-cooled, could it be dust in the heatsinks? My laptop was
overheating recently (getting over 90 Celsius), and I found that a 1/4"
layer of dust was blocking the heatsinks.

I don't know if you want to take apart your controller to check that,
though, it might void your warranty.

-Morgan LaMoore

On 8/19/07, Mark Dutko <[email protected]> wrote:
>
> That's what I was thinking- It should be over cooled I would think???
>
> Mark
>
David Brandt wrote:
>
> > That's the reply I got - of course it's over 100 here, and it
> > typically flashes towards the end of the hot afternoon drive, so I
> > can believe it's getting hot. It's hard to believe yours is...
> >
> >
> >
> >
> >
> > David Brandt
> >
> >
> > ----- Original Message ----
> > From: Mark Dutko <[email protected]>
> > To: [email protected]
> > Sent: Sunday, August 19, 2007 8:26:56 PM
> > Subject: [EVDL] Zilla Engine Light Blinking
> >
> >
> > I drove my Yaris on the Freeway today and never pulled more than 60
> > battery amps, the engine light would blink every once and a while
> > after the first 5 miles or so. I have the Ev source cooling kit and a
> > fan blowing on the radiator. Is this a temp warning? It's less than
> > 70 outside and I thought I had the controller over cooled. It has
> > also blinked in the evening when it is under 60 outside and using the
> > controller harder.
> >
> >
> > Thanks,
> >
> > Mark
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
> >
> >
> > ______________________________________________________________________
> > ______________
> > Yahoo! oneSearch: Finally, mobile search
> > that gives answers, not web links.
> > http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
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Discussion Starter #5
Overcooled? What's it going to do at -20F in Chicago in January? Is there
something I need to know? I have to wonder if it's a coolant flow problem
or a temp sensor that's got a mind of it's own?


----- Original Message -----
From: "Mark Dutko" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Sunday, August 19, 2007 8:44 PM
Subject: Re: [EVDL] Zilla Engine Light Blinking


> That's what I was thinking- It should be over cooled I would think???
>
> Mark
>
David Brandt wrote:
>
>> That's the reply I got - of course it's over 100 here, and it
>> typically flashes towards the end of the hot afternoon drive, so I
>> can believe it's getting hot. It's hard to believe yours is...
>>
>>
>>
>>
>>
>> David Brandt
>>
>>
>> ----- Original Message ----
>> From: Mark Dutko <[email protected]>
>> To: [email protected]
>> Sent: Sunday, August 19, 2007 8:26:56 PM
>> Subject: [EVDL] Zilla Engine Light Blinking
>>
>>
>> I drove my Yaris on the Freeway today and never pulled more than 60
>> battery amps, the engine light would blink every once and a while
>> after the first 5 miles or so. I have the Ev source cooling kit and a
>> fan blowing on the radiator. Is this a temp warning? It's less than
>> 70 outside and I thought I had the controller over cooled. It has
>> also blinked in the evening when it is under 60 outside and using the
>> controller harder.
>>
>>
>> Thanks,
>>
>> Mark
>>
>> _______________________________________________
>> For subscription options, see
>> http://lists.sjsu.edu/mailman/listinfo/ev
>>
>>
>>
>> ______________________________________________________________________
>> ______________
>> Yahoo! oneSearch: Finally, mobile search
>> that gives answers, not web links.
>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
>>
>> _______________________________________________
>> For subscription options, see
>> http://lists.sjsu.edu/mailman/listinfo/ev
>>
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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Discussion Starter #6
Water cooled, radiator, fan from EV source...


Morgan LaMoore wrote:

> If it's air-cooled, could it be dust in the heatsinks? My laptop was
> overheating recently (getting over 90 Celsius), and I found that a
> 1/4"
> layer of dust was blocking the heatsinks.
>
> I don't know if you want to take apart your controller to check that,
> though, it might void your warranty.
>
> -Morgan LaMoore
>
> On 8/19/07, Mark Dutko <[email protected]> wrote:
>>
>> That's what I was thinking- It should be over cooled I would think???
>>
>> Mark
>> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
>>
>>> That's the reply I got - of course it's over 100 here, and it
>>> typically flashes towards the end of the hot afternoon drive, so I
>>> can believe it's getting hot. It's hard to believe yours is...
>>>
>>>
>>>
>>>
>>>
>>> David Brandt
>>>
>>>
>>> ----- Original Message ----
>>> From: Mark Dutko <[email protected]>
>>> To: [email protected]
>>> Sent: Sunday, August 19, 2007 8:26:56 PM
>>> Subject: [EVDL] Zilla Engine Light Blinking
>>>
>>>
>>> I drove my Yaris on the Freeway today and never pulled more than 60
>>> battery amps, the engine light would blink every once and a while
>>> after the first 5 miles or so. I have the Ev source cooling kit
>>> and a
>>> fan blowing on the radiator. Is this a temp warning? It's less than
>>> 70 outside and I thought I had the controller over cooled. It has
>>> also blinked in the evening when it is under 60 outside and using
>>> the
>>> controller harder.
>>>
>>>
>>> Thanks,
>>>
>>> Mark
>>>
>>> _______________________________________________
>>> For subscription options, see
>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>
>>>
>>>
>>> ____________________________________________________________________
>>> __
>>> ______________
>>> Yahoo! oneSearch: Finally, mobile search
>>> that gives answers, not web links.
>>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
>>>
>>> _______________________________________________
>>> For subscription options, see
>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>
>>
>> _______________________________________________
>> For subscription options, see
>> http://lists.sjsu.edu/mailman/listinfo/ev
>>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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Discussion Starter #7
I bled all viable bubbles out of the system, the radiator does get
war and the brass fitting on the pump is quite warm so I assume the
coolant is flowing..


Marty Hewes wrote:

> Overcooled? What's it going to do at -20F in Chicago in January?
> Is there
> something I need to know? I have to wonder if it's a coolant flow
> problem
> or a temp sensor that's got a mind of it's own?
>
>
> ----- Original Message -----
> From: "Mark Dutko" <[email protected]>
> To: "Electric Vehicle Discussion List" <[email protected]>
> Sent: Sunday, August 19, 2007 8:44 PM
> Subject: Re: [EVDL] Zilla Engine Light Blinking
>
>
>> That's what I was thinking- It should be over cooled I would think???
>>
>> Mark
>> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
>>
>>> That's the reply I got - of course it's over 100 here, and it
>>> typically flashes towards the end of the hot afternoon drive, so I
>>> can believe it's getting hot. It's hard to believe yours is...
>>>
>>>
>>>
>>>
>>>
>>> David Brandt
>>>
>>>
>>> ----- Original Message ----
>>> From: Mark Dutko <[email protected]>
>>> To: [email protected]
>>> Sent: Sunday, August 19, 2007 8:26:56 PM
>>> Subject: [EVDL] Zilla Engine Light Blinking
>>>
>>>
>>> I drove my Yaris on the Freeway today and never pulled more than 60
>>> battery amps, the engine light would blink every once and a while
>>> after the first 5 miles or so. I have the Ev source cooling kit
>>> and a
>>> fan blowing on the radiator. Is this a temp warning? It's less than
>>> 70 outside and I thought I had the controller over cooled. It has
>>> also blinked in the evening when it is under 60 outside and using
>>> the
>>> controller harder.
>>>
>>>
>>> Thanks,
>>>
>>> Mark
>>>
>>> _______________________________________________
>>> For subscription options, see
>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>
>>>
>>>
>>> ____________________________________________________________________
>>> __
>>> ______________
>>> Yahoo! oneSearch: Finally, mobile search
>>> that gives answers, not web links.
>>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
>>>
>>> _______________________________________________
>>> For subscription options, see
>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>
>>
>> _______________________________________________
>> For subscription options, see
>> http://lists.sjsu.edu/mailman/listinfo/ev
>>
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
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Discussion Starter #8
Not likely it overcool. I ran the Zilla at -33 below and that's even with a
large radiator fan, large holding tank and a 1 gallon per minute pump, and
also a filter air 150 CFM Dayton blower.

One LED is a low voltage indicator, and will flash when the main battery
pack goes below the preset advance warning limit you program in that should
be about 5 volts above the low warning limit, where it should stay on
steady.

The other LED is a pre-charge status that lights up when you start turning
on the contactor circuit and then both lights should go off after start up.

Also check the trouble codes and clear them out to see what happens. It also
could be a loose or high resistance battery wire or may be a contactor
bounce that could show a intermitted higher resistance.

Roland




----- Original Message -----
From: "Mark Dutko" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Sunday, August 19, 2007 8:17 PM
Subject: Re: [EVDL] Zilla Engine Light Blinking


> I bled all viable bubbles out of the system, the radiator does get
> war and the brass fitting on the pump is quite warm so I assume the
> coolant is flowing..
>
>
>
Marty Hewes wrote:
>
> > Overcooled? What's it going to do at -20F in Chicago in January?
> > Is there
> > something I need to know? I have to wonder if it's a coolant flow
> > problem
> > or a temp sensor that's got a mind of it's own?
> >
> >
> > ----- Original Message -----
> > From: "Mark Dutko" <[email protected]>
> > To: "Electric Vehicle Discussion List" <[email protected]>
> > Sent: Sunday, August 19, 2007 8:44 PM
> > Subject: Re: [EVDL] Zilla Engine Light Blinking
> >
> >
> >> That's what I was thinking- It should be over cooled I would think???
> >>
> >> Mark
> >> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
> >>
> >>> That's the reply I got - of course it's over 100 here, and it
> >>> typically flashes towards the end of the hot afternoon drive, so I
> >>> can believe it's getting hot. It's hard to believe yours is...
> >>>
> >>>
> >>>
> >>>
> >>>
> >>> David Brandt
> >>>
> >>>
> >>> ----- Original Message ----
> >>> From: Mark Dutko <[email protected]>
> >>> To: [email protected]
> >>> Sent: Sunday, August 19, 2007 8:26:56 PM
> >>> Subject: [EVDL] Zilla Engine Light Blinking
> >>>
> >>>
> >>> I drove my Yaris on the Freeway today and never pulled more than 60
> >>> battery amps, the engine light would blink every once and a while
> >>> after the first 5 miles or so. I have the Ev source cooling kit
> >>> and a
> >>> fan blowing on the radiator. Is this a temp warning? It's less than
> >>> 70 outside and I thought I had the controller over cooled. It has
> >>> also blinked in the evening when it is under 60 outside and using
> >>> the
> >>> controller harder.
> >>>
> >>>
> >>> Thanks,
> >>>
> >>> Mark
> >>>
> >>> _______________________________________________
> >>> For subscription options, see
> >>> http://lists.sjsu.edu/mailman/listinfo/ev
> >>>
> >>>
> >>>
> >>> ____________________________________________________________________
> >>> __
> >>> ______________
> >>> Yahoo! oneSearch: Finally, mobile search
> >>> that gives answers, not web links.
> >>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
> >>>
> >>> _______________________________________________
> >>> For subscription options, see
> >>> http://lists.sjsu.edu/mailman/listinfo/ev
> >>>
> >>
> >> _______________________________________________
> >> For subscription options, see
> >> http://lists.sjsu.edu/mailman/listinfo/ev
> >>
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
> _______________________________________________
> For subscription options, see
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Discussion Starter #9
In a message dated 8/19/2007 5:52:21 PM US Mountain Standard Time,
[email protected] writes:
> Re: [EVDL] Zilla Engine Light Blinking
> Date:8/19/2007 5:52:21 PM US Mountain Standard Time
> From:[email protected]
> Reply-to:[email protected]xxx.edu
> To:[email protected]
> Received from Internet:
> My zilla in my new S10 does have the warm lite blinking at about 20 miles
> but I do not have a fan on the radiator.I do also have a 2 quart resivor in the
> loop.While I have been racing the past 2 Friday nights the warm light has
> not come on. Dennis Berube
>
>
> That's the reply I got - of course it's over 100 here, and it typically
> flashes towards the end of the hot afternoon drive, so I can believe it's getting
> hot. It's hard to believe yours is...
>
>
>
>
>
> David Brandt
>
>
> ----- Original Message ----
> From: Mark Dutko <[email protected]>
> To: [email protected]
> Sent: Sunday, August 19, 2007 8:26:56 PM
> Subject: [EVDL] Zilla Engine Light Blinking
>
>
> I drove my Yaris on the Freeway today and never pulled more than 60
> battery amps, the engine light would blink every once and a while
> after the first 5 miles or so. I have the Ev source cooling kit and a
> fan blowing on the radiator. Is this a temp warning? It's less than
> 70 outside and I thought I had the controller over cooled. It has
> also blinked in the evening when it is under 60 outside and using the
> controller harder.
>
>
> Thanks,
>
> Mark

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Discussion Starter #10
My first guess would be overheating, remember when it flashes to ask
yourself what were you doing a mile ago.

If your system is under sized, the heat accumulates and shows up with a
delay.

I had a problem when I first got that very same pump, I just didn't have
all the air out and it would get a air bubble in it. Once that bubble of
air got hot, it kinda vapor locked.

Plug in the notebook and record it. :)

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Discussion Starter #11
Thanks Roland- I will check my codes again. My engine light does come
on at the key turn and then off at start- normal operation. Since
this flashing only occurs after driving a while could it be a cable
loosening under load? Or, if it were a contactor issue would it not
be at startup only? I find it difficult to believe that the
controller needs such extreme cooling at 50 battery amps to keep it
from reaching a high temp. Is there a list of all the issues that
cause a blinking engine light for the Zilla or is it just the ones
you mentioned? MY LBV is at 36 now so that is not the problem and it
happens on a full charge..



M




Roland Wiench wrote:

> Not likely it overcool. I ran the Zilla at -33 below and that's
> even with a
> large radiator fan, large holding tank and a 1 gallon per minute
> pump, and
> also a filter air 150 CFM Dayton blower.
>
> One LED is a low voltage indicator, and will flash when the main
> battery
> pack goes below the preset advance warning limit you program in
> that should
> be about 5 volts above the low warning limit, where it should stay on
> steady.
>
> The other LED is a pre-charge status that lights up when you start
> turning
> on the contactor circuit and then both lights should go off after
> start up.
>
> Also check the trouble codes and clear them out to see what
> happens. It also
> could be a loose or high resistance battery wire or may be a contactor
> bounce that could show a intermitted higher resistance.
>
> Roland
>
>
>
>
> ----- Original Message -----
> From: "Mark Dutko" <[email protected]>
> To: "Electric Vehicle Discussion List" <[email protected]>
> Sent: Sunday, August 19, 2007 8:17 PM
> Subject: Re: [EVDL] Zilla Engine Light Blinking
>
>
>> I bled all viable bubbles out of the system, the radiator does get
>> war and the brass fitting on the pump is quite warm so I assume the
>> coolant is flowing..
>>
>>
>> On Aug 19, 2007, at 6:57 PM, Marty Hewes wrote:
>>
>>> Overcooled? What's it going to do at -20F in Chicago in January?
>>> Is there
>>> something I need to know? I have to wonder if it's a coolant flow
>>> problem
>>> or a temp sensor that's got a mind of it's own?
>>>
>>>
>>> ----- Original Message -----
>>> From: "Mark Dutko" <[email protected]>
>>> To: "Electric Vehicle Discussion List" <[email protected]>
>>> Sent: Sunday, August 19, 2007 8:44 PM
>>> Subject: Re: [EVDL] Zilla Engine Light Blinking
>>>
>>>
>>>> That's what I was thinking- It should be over cooled I would
>>>> think???
>>>>
>>>> Mark
>>>> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
>>>>
>>>>> That's the reply I got - of course it's over 100 here, and it
>>>>> typically flashes towards the end of the hot afternoon drive, so I
>>>>> can believe it's getting hot. It's hard to believe yours is...
>>>>>
>>>>>
>>>>>
>>>>>
>>>>>
>>>>> David Brandt
>>>>>
>>>>>
>>>>> ----- Original Message ----
>>>>> From: Mark Dutko <[email protected]>
>>>>> To: [email protected]
>>>>> Sent: Sunday, August 19, 2007 8:26:56 PM
>>>>> Subject: [EVDL] Zilla Engine Light Blinking
>>>>>
>>>>>
>>>>> I drove my Yaris on the Freeway today and never pulled more
>>>>> than 60
>>>>> battery amps, the engine light would blink every once and a while
>>>>> after the first 5 miles or so. I have the Ev source cooling kit
>>>>> and a
>>>>> fan blowing on the radiator. Is this a temp warning? It's less
>>>>> than
>>>>> 70 outside and I thought I had the controller over cooled. It has
>>>>> also blinked in the evening when it is under 60 outside and using
>>>>> the
>>>>> controller harder.
>>>>>
>>>>>
>>>>> Thanks,
>>>>>
>>>>> Mark
>>>>>
>>>>> _______________________________________________
>>>>> For subscription options, see
>>>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>>>
>>>>>
>>>>>
>>>>> __________________________________________________________________
>>>>> __
>>>>> __
>>>>> ______________
>>>>> Yahoo! oneSearch: Finally, mobile search
>>>>> that gives answers, not web links.
>>>>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
>>>>>
>>>>> _______________________________________________
>>>>> For subscription options, see
>>>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>>>
>>>>
>>>> _______________________________________________
>>>> For subscription options, see
>>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>>
>>>
>>> _______________________________________________
>>> For subscription options, see
>>> http://lists.sjsu.edu/mailman/listinfo/ev
>>>
>>
>> _______________________________________________
>> For subscription options, see
>> http://lists.sjsu.edu/mailman/listinfo/ev
>>
>
> _______________________________________________
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Discussion Starter #12
I think all the air is out, even the smallest bubble, I am running
100% coolant so perhaps a water mixture would transfer heat better?

M

Jeff Shanab wrote:

> My first guess would be overheating, remember when it flashes to ask
> yourself what were you doing a mile ago.
>
> If your system is under sized, the heat accumulates and shows up
> with a
> delay.
>
> I had a problem when I first got that very same pump, I just didn't
> have
> all the air out and it would get a air bubble in it. Once that
> bubble of
> air got hot, it kinda vapor locked.
>
> Plug in the notebook and record it. :)
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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Discussion Starter #13
Mark wrote:

>perhaps a water mixture would transfer heat better?

Absolutely:

http://www.stewartcomponents.com/tech_tips/Tech_Tips_4.htm

If you run straight water, add a bottle of this for corrosion
protection(can be had at walmart or any parts store)

http://www.prestone.com/products/print.php?fam=2&num=4&name=Prestone+R+Cooling+System+Treatment&regTM=1

(it's in a tiny little bottle on the shelf)

Or consider this stuff: http://www.evanscooling.com/

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Discussion Starter #14
Yes, water would transfer better. in this case we are talking about two
such exchanges, so this may be a factor. The only way to tel is plug in
a notebook and capture the problem.

Something Roland mentioned got my attention. Could the dc-dc be browning
out and the 12V supplied be dropping below the threshold. This also may
occur at end of drive and under acceleration. Does it happen when
cruising, accelerating, or accelerating after a long cruise.?

_______________________________________________
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70 Posts
Discussion Starter #15
Mark,

How does the coolant flow in your system? It should go from the coolant
tank to the pump to the Zilla to the radiator and then back to the tank.

Can you see the coolant returning to the tank? Is the flow good?

Have you run the pump in standalone mode, just pumping coolant from the
tank and back again? This would allow you to see what the max flow
returning to the tank looks like. You could compare this to the return
flow in your system - maybe there's a blockage somewhere?

Ralph


Mark Dutko writes:
>
> I bled all viable bubbles out of the system, the radiator does get
> war and the brass fitting on the pump is quite warm so I assume the
> coolant is flowing..
>
>
>
Marty Hewes wrote:
>
> > Overcooled? What's it going to do at -20F in Chicago in January?
> > Is there
> > something I need to know? I have to wonder if it's a coolant flow
> > problem
> > or a temp sensor that's got a mind of it's own?
> >
> >
> > ----- Original Message -----
> > From: "Mark Dutko" <[email protected]>
> > To: "Electric Vehicle Discussion List" <[email protected]>
> > Sent: Sunday, August 19, 2007 8:44 PM
> > Subject: Re: [EVDL] Zilla Engine Light Blinking
> >
> >
> >> That's what I was thinking- It should be over cooled I would think???
> >>
> >> Mark
> >> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
> >>
> >>> That's the reply I got - of course it's over 100 here, and it
> >>> typically flashes towards the end of the hot afternoon drive, so I
> >>> can believe it's getting hot. It's hard to believe yours is...
> >>>
> >>>
> >>>
> >>>
> >>>
> >>> David Brandt
> >>>
> >>>
> >>> ----- Original Message ----
> >>> From: Mark Dutko <[email protected]>
> >>> To: [email protected]
> >>> Sent: Sunday, August 19, 2007 8:26:56 PM
> >>> Subject: [EVDL] Zilla Engine Light Blinking
> >>>
> >>>
> >>> I drove my Yaris on the Freeway today and never pulled more than 60
> >>> battery amps, the engine light would blink every once and a while
> >>> after the first 5 miles or so. I have the Ev source cooling kit
> >>> and a
> >>> fan blowing on the radiator. Is this a temp warning? It's less than
> >>> 70 outside and I thought I had the controller over cooled. It has
> >>> also blinked in the evening when it is under 60 outside and using
> >>> the
> >>> controller harder.
> >>>
> >>>
> >>> Thanks,
> >>>
> >>> Mark
> >>>
> >>> _______________________________________________
> >>> For subscription options, see
> >>> http://lists.sjsu.edu/mailman/listinfo/ev
> >>>
> >>>
> >>>
> >>> ____________________________________________________________________
> >>> __
> >>> ______________
> >>> Yahoo! oneSearch: Finally, mobile search
> >>> that gives answers, not web links.
> >>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
> >>>
> >>> _______________________________________________
> >>> For subscription options, see
> >>> http://lists.sjsu.edu/mailman/listinfo/ev
> >>>
> >>
> >> _______________________________________________
> >> For subscription options, see
> >> http://lists.sjsu.edu/mailman/listinfo/ev
> >>
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

_______________________________________________
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70 Posts
Discussion Starter #16
My coolant flow is from the Zilla which is a little lower than tank. A 1
gallon per min pump is plug into the bottom of this tank and then goes to a
radiator that is mounted in front of the A/C radiator with a large electric
fan on it.

The radiator has a drain value on it. From the radiator the lines are
double foam insulated which are about 2 inches in outside diameter or a 3/8
hose, directly to the Zilla.

I find if I pump it from the tank to the Zilla, the tank which is a
expansion tank for a Pontiac with air vents is place higher than the Zilla,
so it can vent, the coolant in the tank gets to the same temperature of the
ambient air, so it is best to cool down the coolent first before its return
to the Zilla.

My Zilla heat sink maximum temperature I even got with only the pump and fan
running, Zilla was not on, was 99 degrees with a ambient temperature of 105
degrees and underhood temperature of 140 degrees.

Roland


----- Original Message -----
From: "Ralph Merwin" <[email protected]>
To: <[email protected]>
Sent: Monday, August 20, 2007 7:10 AM
Subject: Re: [EVDL] Zilla Engine Light Blinking


>
> Mark,
>
> How does the coolant flow in your system? It should go from the coolant
> tank to the pump to the Zilla to the radiator and then back to the tank.
>
> Can you see the coolant returning to the tank? Is the flow good?
>
> Have you run the pump in standalone mode, just pumping coolant from the
> tank and back again? This would allow you to see what the max flow
> returning to the tank looks like. You could compare this to the return
> flow in your system - maybe there's a blockage somewhere?
>
> Ralph
>
>
> Mark Dutko writes:
> >
> > I bled all viable bubbles out of the system, the radiator does get
> > war and the brass fitting on the pump is quite warm so I assume the
> > coolant is flowing..
> >
> >
> >
Marty Hewes wrote:
> >
> > > Overcooled? What's it going to do at -20F in Chicago in January?
> > > Is there
> > > something I need to know? I have to wonder if it's a coolant flow
> > > problem
> > > or a temp sensor that's got a mind of it's own?
> > >
> > >
> > > ----- Original Message -----
> > > From: "Mark Dutko" <[email protected]>
> > > To: "Electric Vehicle Discussion List" <[email protected]>
> > > Sent: Sunday, August 19, 2007 8:44 PM
> > > Subject: Re: [EVDL] Zilla Engine Light Blinking
> > >
> > >
> > >> That's what I was thinking- It should be over cooled I would think???
> > >>
> > >> Mark
> > >> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
> > >>
> > >>> That's the reply I got - of course it's over 100 here, and it
> > >>> typically flashes towards the end of the hot afternoon drive, so I
> > >>> can believe it's getting hot. It's hard to believe yours is...
> > >>>
> > >>>
> > >>>
> > >>>
> > >>>
> > >>> David Brandt
> > >>>
> > >>>
> > >>> ----- Original Message ----
> > >>> From: Mark Dutko <[email protected]>
> > >>> To: [email protected]
> > >>> Sent: Sunday, August 19, 2007 8:26:56 PM
> > >>> Subject: [EVDL] Zilla Engine Light Blinking
> > >>>
> > >>>
> > >>> I drove my Yaris on the Freeway today and never pulled more than 60
> > >>> battery amps, the engine light would blink every once and a while
> > >>> after the first 5 miles or so. I have the Ev source cooling kit
> > >>> and a
> > >>> fan blowing on the radiator. Is this a temp warning? It's less than
> > >>> 70 outside and I thought I had the controller over cooled. It has
> > >>> also blinked in the evening when it is under 60 outside and using
> > >>> the
> > >>> controller harder.
> > >>>
> > >>>
> > >>> Thanks,
> > >>>
> > >>> Mark
> > >>>
> > >>> _______________________________________________
> > >>> For subscription options, see
> > >>> http://lists.sjsu.edu/mailman/listinfo/ev
> > >>>
> > >>>
> > >>>
> > >>> ____________________________________________________________________
> > >>> __
> > >>> ______________
> > >>> Yahoo! oneSearch: Finally, mobile search
> > >>> that gives answers, not web links.
> > >>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
> > >>>
> > >>> _______________________________________________
> > >>> For subscription options, see
> > >>> http://lists.sjsu.edu/mailman/listinfo/ev
> > >>>
> > >>
> > >> _______________________________________________
> > >> For subscription options, see
> > >> http://lists.sjsu.edu/mailman/listinfo/ev
> > >>
> > >
> > > _______________________________________________
> > > For subscription options, see
> > > http://lists.sjsu.edu/mailman/listinfo/ev
> > >
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

_______________________________________________
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70 Posts
Discussion Starter #17
Hmmm.....my Zilla manual says you need a 2 gallon per minute pump. Could be
that you just don't have enough flow by the time you go through your system.

Jerry

On 8/20/07, Roland Wiench <[email protected]> wrote:
>
> My coolant flow is from the Zilla which is a little lower than tank. A 1
> gallon per min pump is plug into the bottom of this tank and then goes to
> a
> radiator that is mounted in front of the A/C radiator with a large
> electric
> fan on it.
>
> The radiator has a drain value on it. From the radiator the lines are
> double foam insulated which are about 2 inches in outside diameter or a
> 3/8
> hose, directly to the Zilla.
>
> I find if I pump it from the tank to the Zilla, the tank which is a
> expansion tank for a Pontiac with air vents is place higher than the
> Zilla,
> so it can vent, the coolant in the tank gets to the same temperature of
> the
> ambient air, so it is best to cool down the coolent first before its
> return
> to the Zilla.
>
> My Zilla heat sink maximum temperature I even got with only the pump and
> fan
> running, Zilla was not on, was 99 degrees with a ambient temperature of
> 105
> degrees and underhood temperature of 140 degrees.
>
> Roland
>
>
> ----- Original Message -----
> From: "Ralph Merwin" <[email protected]>
> To: <[email protected]>
> Sent: Monday, August 20, 2007 7:10 AM
> Subject: Re: [EVDL] Zilla Engine Light Blinking
>
>
> >
> > Mark,
> >
> > How does the coolant flow in your system? It should go from the coolant
> > tank to the pump to the Zilla to the radiator and then back to the tank.
> >
> > Can you see the coolant returning to the tank? Is the flow good?
> >
> > Have you run the pump in standalone mode, just pumping coolant from the
> > tank and back again? This would allow you to see what the max flow
> > returning to the tank looks like. You could compare this to the return
> > flow in your system - maybe there's a blockage somewhere?
> >
> > Ralph
> >
> >
> > Mark Dutko writes:
> > >
> > > I bled all viable bubbles out of the system, the radiator does get
> > > war and the brass fitting on the pump is quite warm so I assume the
> > > coolant is flowing..
> > >
> > >
> > >
Marty Hewes wrote:
> > >
> > > > Overcooled? What's it going to do at -20F in Chicago in January?
> > > > Is there
> > > > something I need to know? I have to wonder if it's a coolant flow
> > > > problem
> > > > or a temp sensor that's got a mind of it's own?
> > > >
> > > >
> > > > ----- Original Message -----
> > > > From: "Mark Dutko" <[email protected]>
> > > > To: "Electric Vehicle Discussion List" <[email protected]>
> > > > Sent: Sunday, August 19, 2007 8:44 PM
> > > > Subject: Re: [EVDL] Zilla Engine Light Blinking
> > > >
> > > >
> > > >> That's what I was thinking- It should be over cooled I would
> think???
> > > >>
> > > >> Mark
> > > >> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
> > > >>
> > > >>> That's the reply I got - of course it's over 100 here, and it
> > > >>> typically flashes towards the end of the hot afternoon drive, so I
> > > >>> can believe it's getting hot. It's hard to believe yours is...
> > > >>>
> > > >>>
> > > >>>
> > > >>>
> > > >>>
> > > >>> David Brandt
> > > >>>
> > > >>>
> > > >>> ----- Original Message ----
> > > >>> From: Mark Dutko <[email protected]>
> > > >>> To: [email protected]
> > > >>> Sent: Sunday, August 19, 2007 8:26:56 PM
> > > >>> Subject: [EVDL] Zilla Engine Light Blinking
> > > >>>
> > > >>>
> > > >>> I drove my Yaris on the Freeway today and never pulled more than
> 60
> > > >>> battery amps, the engine light would blink every once and a while
> > > >>> after the first 5 miles or so. I have the Ev source cooling kit
> > > >>> and a
> > > >>> fan blowing on the radiator. Is this a temp warning? It's less
> than
> > > >>> 70 outside and I thought I had the controller over cooled. It has
> > > >>> also blinked in the evening when it is under 60 outside and using
> > > >>> the
> > > >>> controller harder.
> > > >>>
> > > >>>
> > > >>> Thanks,
> > > >>>
> > > >>> Mark
> > > >>>
> > > >>> _______________________________________________
> > > >>> For subscription options, see
> > > >>> http://lists.sjsu.edu/mailman/listinfo/ev
> > > >>>
> > > >>>
> > > >>>
> > > >>>
> ____________________________________________________________________
> > > >>> __
> > > >>> ______________
> > > >>> Yahoo! oneSearch: Finally, mobile search
> > > >>> that gives answers, not web links.
> > > >>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
> > > >>>
> > > >>> _______________________________________________
> > > >>> For subscription options, see
> > > >>> http://lists.sjsu.edu/mailman/listinfo/ev
> > > >>>
> > > >>
> > > >> _______________________________________________
> > > >> For subscription options, see
> > > >> http://lists.sjsu.edu/mailman/listinfo/ev
> > > >>
> > > >
> > > > _______________________________________________
> > > > For subscription options, see
> > > > http://lists.sjsu.edu/mailman/listinfo/ev
> > > >
> > >
> > > _______________________________________________
> > > For subscription options, see
> > > http://lists.sjsu.edu/mailman/listinfo/ev
> > >
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
_______________________________________________
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70 Posts
Discussion Starter #18
It's not he DC/DC, and I have an aux battery, this is during constant
cruising at 40-50 amps with a good charge. Would the water make a
significant enough improvement that it is worth re-bleeding the system?

Mark


Jeff Shanab wrote:

> Yes, water would transfer better. in this case we are talking about
> two
> such exchanges, so this may be a factor. The only way to tel is
> plug in
> a notebook and capture the problem.
>
> Something Roland mentioned got my attention. Could the dc-dc be
> browning
> out and the 12V supplied be dropping below the threshold. This also
> may
> occur at end of drive and under acceleration. Does it happen when
> cruising, accelerating, or accelerating after a long cruise.?
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

_______________________________________________
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70 Posts
Discussion Starter #19
----- Original Message -----
From: "Gerald Wagner" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Monday, August 20, 2007 8:21 AM
Subject: Re: [EVDL] Zilla Engine Light Blinking


> Hmmm.....my Zilla manual says you need a 2 gallon per minute pump. Could
> be
> that you just don't have enough flow by the time you go through your
> system.
>
> Jerry

I am using a Maxi-Jet 1200 MarineLand pump which Otmar said works good. It
may be a little more then 1 gallon per minute. Also the pump is at a high
point in the installation, so the head pressure is not that great if you was
to pump upward.

Roland
>
> On 8/20/07, Roland Wiench <[email protected]> wrote:
> >
> > My coolant flow is from the Zilla which is a little lower than tank. A
> > 1
> > gallon per min pump is plug into the bottom of this tank and then goes
> > to
> > a
> > radiator that is mounted in front of the A/C radiator with a large
> > electric
> > fan on it.
> >
> > The radiator has a drain value on it. From the radiator the lines are
> > double foam insulated which are about 2 inches in outside diameter or a
> > 3/8
> > hose, directly to the Zilla.
> >
> > I find if I pump it from the tank to the Zilla, the tank which is a
> > expansion tank for a Pontiac with air vents is place higher than the
> > Zilla,
> > so it can vent, the coolant in the tank gets to the same temperature of
> > the
> > ambient air, so it is best to cool down the coolent first before its
> > return
> > to the Zilla.
> >
> > My Zilla heat sink maximum temperature I even got with only the pump and
> > fan
> > running, Zilla was not on, was 99 degrees with a ambient temperature of
> > 105
> > degrees and underhood temperature of 140 degrees.
> >
> > Roland
> >
> >
> > ----- Original Message -----
> > From: "Ralph Merwin" <[email protected]>
> > To: <[email protected]>
> > Sent: Monday, August 20, 2007 7:10 AM
> > Subject: Re: [EVDL] Zilla Engine Light Blinking
> >
> >
> > >
> > > Mark,
> > >
> > > How does the coolant flow in your system? It should go from the
> > > coolant
> > > tank to the pump to the Zilla to the radiator and then back to the
> > > tank.
> > >
> > > Can you see the coolant returning to the tank? Is the flow good?
> > >
> > > Have you run the pump in standalone mode, just pumping coolant from
> > > the
> > > tank and back again? This would allow you to see what the max flow
> > > returning to the tank looks like. You could compare this to the
> > > return
> > > flow in your system - maybe there's a blockage somewhere?
> > >
> > > Ralph
> > >
> > >
> > > Mark Dutko writes:
> > > >
> > > > I bled all viable bubbles out of the system, the radiator does get
> > > > war and the brass fitting on the pump is quite warm so I assume the
> > > > coolant is flowing..
> > > >
> > > >
> > > >
Marty Hewes wrote:
> > > >
> > > > > Overcooled? What's it going to do at -20F in Chicago in January?
> > > > > Is there
> > > > > something I need to know? I have to wonder if it's a coolant flow
> > > > > problem
> > > > > or a temp sensor that's got a mind of it's own?
> > > > >
> > > > >
> > > > > ----- Original Message -----
> > > > > From: "Mark Dutko" <[email protected]>
> > > > > To: "Electric Vehicle Discussion List" <[email protected]>
> > > > > Sent: Sunday, August 19, 2007 8:44 PM
> > > > > Subject: Re: [EVDL] Zilla Engine Light Blinking
> > > > >
> > > > >
> > > > >> That's what I was thinking- It should be over cooled I would
> > think???
> > > > >>
> > > > >> Mark
> > > > >> On Aug 19, 2007, at 5:50 PM, David Brandt wrote:
> > > > >>
> > > > >>> That's the reply I got - of course it's over 100 here, and it
> > > > >>> typically flashes towards the end of the hot afternoon drive, so
> > > > >>> I
> > > > >>> can believe it's getting hot. It's hard to believe yours is...
> > > > >>>
> > > > >>>
> > > > >>>
> > > > >>>
> > > > >>>
> > > > >>> David Brandt
> > > > >>>
> > > > >>>
> > > > >>> ----- Original Message ----
> > > > >>> From: Mark Dutko <[email protected]>
> > > > >>> To: [email protected]
> > > > >>> Sent: Sunday, August 19, 2007 8:26:56 PM
> > > > >>> Subject: [EVDL] Zilla Engine Light Blinking
> > > > >>>
> > > > >>>
> > > > >>> I drove my Yaris on the Freeway today and never pulled more than
> > 60
> > > > >>> battery amps, the engine light would blink every once and a
> > > > >>> while
> > > > >>> after the first 5 miles or so. I have the Ev source cooling kit
> > > > >>> and a
> > > > >>> fan blowing on the radiator. Is this a temp warning? It's less
> > than
> > > > >>> 70 outside and I thought I had the controller over cooled. It
> > > > >>> has
> > > > >>> also blinked in the evening when it is under 60 outside and
> > > > >>> using
> > > > >>> the
> > > > >>> controller harder.
> > > > >>>
> > > > >>>
> > > > >>> Thanks,
> > > > >>>
> > > > >>> Mark
> > > > >>>
> > > > >>> _______________________________________________
> > > > >>> For subscription options, see
> > > > >>> http://lists.sjsu.edu/mailman/listinfo/ev
> > > > >>>
> > > > >>>
> > > > >>>
> > > > >>>
> > ____________________________________________________________________
> > > > >>> __
> > > > >>> ______________
> > > > >>> Yahoo! oneSearch: Finally, mobile search
> > > > >>> that gives answers, not web links.
> > > > >>> http://mobile.yahoo.com/mobileweb/onesearch?refer=1ONXIC
> > > > >>>
> > > > >>> _______________________________________________
> > > > >>> For subscription options, see
> > > > >>> http://lists.sjsu.edu/mailman/listinfo/ev
> > > > >>>
> > > > >>
> > > > >> _______________________________________________
> > > > >> For subscription options, see
> > > > >> http://lists.sjsu.edu/mailman/listinfo/ev
> > > > >>
> > > > >
> > > > > _______________________________________________
> > > > > For subscription options, see
> > > > > http://lists.sjsu.edu/mailman/listinfo/ev
> > > > >
> > > >
> > > > _______________________________________________
> > > > For subscription options, see
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> > > >
> > >
> > > _______________________________________________
> > > For subscription options, see
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> > >
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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70 Posts
Discussion Starter #20
Mark and other Zilla troubleshooters,

I haven't seen a post where you've identified that the heat is actually the
problem. Have you checked the trouble codes yet?

Not exactly related, but along the lines of heating up a Zilla, I have
pushed my Z2K for 15-20 minutes straight, under "spirited" driving in Joule
Injected with the water pump inadvertently left off. The only ill effect was
that the Zilla gradually "de-tuned" performance and lowered its maximum
current output. It becomes fairly obvious when you can only pull 1100 amps
or so when you're used to the full 2000. It's also one of the more
interesting plots when you bring the data up in FasTrack: you can see the
temperature going up, up up and the current limit ("available current")
going down, down, down. It's just what you'd expect from such a wonderful,
refined controller.

Matt Graham

-----Original Message-----
From: [email protected] [mailto:[email protected]] On Behalf
Of Mark Dutko
Sent: Monday, August 20, 2007 10:29 AM
To: Electric Vehicle Discussion List
Subject: Re: [EVDL] Zilla Engine Light Blinking

It's not he DC/DC, and I have an aux battery, this is during constant
cruising at 40-50 amps with a good charge. Would the water make a
significant enough improvement that it is worth re-bleeding the system?

Mark


Jeff Shanab wrote:

> Yes, water would transfer better. in this case we are talking about
> two
> such exchanges, so this may be a factor. The only way to tel is
> plug in
> a notebook and capture the problem.
>
> Something Roland mentioned got my attention. Could the dc-dc be
> browning
> out and the 12V supplied be dropping below the threshold. This also
> may
> occur at end of drive and under acceleration. Does it happen when
> cruising, accelerating, or accelerating after a long cruise.?
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev

_______________________________________________
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