KAD32 Supercharger issue - First sign of insanity

SheldonEP91 said:
I still need to get a proper signal generator, had one that went kaboom and was beyond being repaired.

So might buy one now since I need to use it also with rev counters.

thanks again for your help, saved some research and testing time! will keep you updated once I find some time and build a small jig.
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this should do the job!
 

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SheldonEP91 said:
I was planing to use Arduino to output the wave for this test jig and also use it to test RPM gauges however I believe the Arduino only outputs max of 980hz so that is out of the question.
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Upgrade to an ESP32 and you will be easily able to generate the sine wave you need, you can also use it as a simple oscilloscope.
 
SheldonEP91 said:
Not sure about the ESP32, I have a node MCU here and can test it with my oscilloscope! thanks for the reminder haha
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The advantage of the ESP32 is that it has a DAC built in (the ESP8266 doesn't). You'll need some extra components to get the signal in the voltage range you want, but you will have full control and you can add extra features, such as a display of the equivalent RPM. More work than buying a ready made one, but if you enjoy tinkering it would be an interesting little project.
 
petem said:
Wouldn't it be a pretty simple job (assuming the parameters are known) to build a supercharger controller using an Arduino?
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Yes it would be trivial to do with an Arduino/ESP8266 etc. You need to know the exact functionality of the VP box (pin connections, voltages, RPM frequency to cut in/out and when the kick down sensor is used etc) FatherTed seems to have all that worked out.

You would need to be very careful with the coding to be 100% sure the supercharger only comes on when it's supposed to, but the parts cost would be in the region of £20-30, with each individual bit replaceable if anything burns out. Add a manual switch to override it if anything goes wrong and you'd have an improved version over the original.
 
I read these are on back order from Volvo until Spring 2025, which means they are ordering a production run from their supplier.
Would be interested to see if the design has changed to offer more protection to the circuit.....I doubt it this late in the game.

I have seen at least rev H, but not really paid much attention to the rev numbers.
 
FatherTed said:
I read these are on back order from Volvo until Spring 2025, which means they are ordering a production run from their supplier.
Would be interested to see if the design has changed to offer more protection to the circuit.....I doubt it this late in the game.

I have seen at least rev H, but not really paid much attention to the rev numbers.
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Hi All,
I am a new member and I’m interested in Father Ted’s refurbing of KAD32 speed controllers. Because I am new I don’t think I can PM would it be possible for Father Ted to PM me so I can reply as I believe he can help?
 
bitsandpcs said:
Hi All,
I am a new member and I’m interested in Father Ted’s refurbing of KAD32 speed controllers. Because I am new I don’t think I can PM would it be possible for Father Ted to PM me so I can reply as I believe he can help?
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I can't PM you because you are new. If you watch the YouTube video in post 10 earlier, my email is in the video description on YouTube.
 
FatherTed said:
I read these are on back order from Volvo until Spring 2025, which means they are ordering a production run from their supplier.
Would be interested to see if the design has changed to offer more protection to the circuit.....I doubt it this late in the game.

I have seen at least rev H, but not really paid much attention to the rev numbers.
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It's not the speed control relay that is at fault when it burns out , it is because the clutch overheats the coil causing it to draw extra current , the wiring loom design is terrible , it uses the reset button fuse . If it had its own 7.5 amp fuse as per the kad 44/300 it would blow when it's failing which tells an owner you need to replace the clutch . From memory the reset button fuse is 10amp .
 
Hi All, I have been researching these Super Chargers in prep to start fault finding and came across this thread. I wonder if any of you could comment on an observation that I have with one of my engines. Both my SC appear to kick in and out at the right revs and the boat gets on the plane lovely - so no issues there. I am wondering if I have a problem building though. One of the units as it switches on, I notice an imediate drop in reves as shown on the rev counter (but appears to be no note change in the engine). I think that also I may see a subtle drop in the charge voltage. Sound wise I have also noted a small squeek occuring, that eventually dispears as the revs get up.
I have not done any fault finding just yet and am initially thinking to check belt tightness, charger oil and any electral connections. I am working on the current theory that the electrical load is causing an issue. These engines are new to me as I am used to old BMC diesels.
 
PhilB9841 said:
Hi All, I have been researching these Super Chargers in prep to start fault finding and came across this thread. I wonder if any of you could comment on an observation that I have with one of my engines. Both my SC appear to kick in and out at the right revs and the boat gets on the plane lovely - so no issues there. I am wondering if I have a problem building though. One of the units as it switches on, I notice an imediate drop in reves as shown on the rev counter (but appears to be no note change in the engine). I think that also I may see a subtle drop in the charge voltage. Sound wise I have also noted a small squeek occuring, that eventually dispears as the revs get up.
I have not done any fault finding just yet and am initially thinking to check belt tightness, charger oil and any electral connections. I am working on the current theory that the electrical load is causing an issue. These engines are new to me as I am used to old BMC diesels.
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FatherTed said:
For the Sine wave 5v P-P is fine, but it's not that fussy.

The digital signal generator is the way to go, but you can start with anything that is cheap just to test the principle. The one in my video was very cheap, but lacks accuracy.

With the digital one I can dial in 1429Hz and the supercharger is running, 1 click to 1430Hz and the supercharger will disengage and this is 100% repeatable. My oscilloscope also confirms the frequency.

What I find with the repairs is owners will play with the speed adjustment when the box is faulty, this puts the box out of adjustment. With the digital signal generator I can adjust it back to the Volvo spec - something I could not do with the cheap one.

For the connector look at 6.3mm 8 way automotive electrical 8 pin male/female connector - its got the right pitch, you just need to adjust the housing slightly, then it fits the Volvo connector.
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I have sent you an email on Sunday regarding my relay which needs fixing 😊
 
I did away with all the complicated electronics and put in a couple of switches!

Could not be happier with it, very confident that nothing can let me down and I can also opt for slightly quieter running by not engaging the SC’s at all!

I put relays in too which offers extra protection!
 
FatherTed said:
The Speed Control Relay can be fixed, it's usually just a £5 transistor that blows. Don't throw anything away, PM me if you want me to take a look at it.
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Very interesting, just had an experience with a burnt out clutch and speed control relay, possibly in conjunction with a faulty alternator - not a nice experience at sea, smoke from clutch everywhere!!! can I ask if you still repair speed control relays please?
 
clinder said:
Very interesting, just had an experience with a burnt out clutch and speed control relay, possibly in conjunction with a faulty alternator - not a nice experience at sea, smoke from clutch everywhere!!! can I ask if you still repair speed control relays please?
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Yes, I do and I have replied to your email, thanks.
 
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