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Unread 12-11-2014, 09:11 AM   #71
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Default Re: Couple of wiring questions.

I think Im realizing something all of the sudden.

Tell me if Im wrong.

You turn the key to on. That lights up the light blue on the solenoid. When you press the pedal, that turns the Blue/White on the solenoid to -48v and the solenoid engages.

Just turning on the key doesn't engage the solenoid. You need the pedal as well.

So, if my MCOR is bad, the Blue/White wont flip to -48v.
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Unread 12-11-2014, 09:32 AM   #72
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Default Re: Couple of wiring questions.

Quote:
Just turning on the key doesn't engage the solenoid. You need the pedal as well.
Yep, You are starting to get it..., but not just the MCOR switch, You need all of those conditions we talked about back in Post #29.

In addition to all that, the MCOR signal has to be above a certain level, I know it is not as high as 25% as that triggers an HPD fault.

I am also sure is not as low as the 1% that your measurements would indicate.

I would guess at least 5% Throttle signal would be needed before the controller "sees" it as a valid signal.

If the resistance from Yellow to Purple is at the most 20Ω as You reported, then replace the MCOR before proceeding.
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Unread 12-11-2014, 09:41 AM   #73
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Default Re: Couple of wiring questions.

I think I understand. My whole problem, I think, is, I had it in my mind that the controller was telling everything what to do.

Looks like everything is telling the controller what to do. The controller is not as smart as I thought. Its really just a switch board.
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Unread 12-11-2014, 10:27 AM   #74
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Default Re: Couple of wiring questions.

Well, I would not say that...

The controller depends on a lot of "sensors" to make the proper decisions, similar to the ECU in your car thinking the fuel mixture is too rich because of a bad signal from an 02 sensor.

In particular the SEPEX Regenerative controller You have is pretty complex, much more so than the simpler, but in my opinion inefficient, Series drive system.

It would be nice if there was a "standard" diagnostic system like the OBDII/CAN for cars that every controller manufacturer had to support. Those chip sets now cost under $5 to integrate into the electronics.
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Unread 12-11-2014, 07:00 PM   #75
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Default Re: Couple of wiring questions.

I ordered an MCOR today. Have the new controller on my bench.

I'm going to wait and hook up the MCOR and see what happens, hoping! that my bad controller (if its bad) doesn't burn it up..

Im guessing if one is going to burn up, it will be the controller before the MCOR..

Sound reasonable??
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Unread 12-11-2014, 08:13 PM   #76
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Default Re: Couple of wiring questions.

There is no way the controller can burn up the new MCOR, so You can try the new MCOR on the old controller do definitely rule the controller as bad or not.
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Unread 12-11-2014, 09:08 PM   #77
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Sergio View Post
There is no way the controller can burn up the new MCOR, so You can try the new MCOR on the old controller do definitely rule the controller as bad or not.
Cool. Thanks a lot for all of your help Sergio!!!!
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Unread 12-14-2014, 04:55 PM   #78
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Default Re: Couple of wiring questions.

I found A lengthy manual on testing pins at the controller as well as MCOR, FWD/REV and dash. I went through all of that and everything checked out. Accept some weird readings on the MCOR as discussed before.

Still have 2.7V at Blk/Wht

Set the meter to 20kΩ, and measure directly at the MCOR pins that correspond to the wire colors below:
From White/Black to Purple: Around 7kΩ I got 6.7
From Yellow to Purple: Pedal up 1k, pedal down 1 through 4.5.. After 4.5 it starts jumping around then when pressed all the way down the meter Goes to 1. I think that's an error reading.

I did however get all positive readings out of the MCOR as it relates to fwd/rev Green and Purple wire and the rest of the whole system.

So waiting for the MCOR

Is there a way to test the motor using the small Orange and Blue from controller to motor? Looks like The main Green and White stay Hot at 48v

Are the green and blue grounds?
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Unread 12-14-2014, 09:50 PM   #79
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Merlinhaggard View Post
I found A lengthy manual on testing pins at the controller as well as MCOR, FWD/REV and dash. I went through all of that and everything checked out. Accept some weird readings on the MCOR as discussed before.

Still have 2.7V at Blk/Wht

Set the meter to 20kΩ, and measure directly at the MCOR pins that correspond to the wire colors below:
From White/Black to Purple: Around 7kΩ I got 6.7
From Yellow to Purple: Pedal up 1k, pedal down 1 through 4.5.. After 4.5 it starts jumping around then when pressed all the way down the meter Goes to 1. I think that's an error reading.

I did however get all positive readings out of the MCOR as it relates to fwd/rev Green and Purple wire and the rest of the whole system.

So waiting for the MCOR

Is there a way to test the motor using the small Orange and Blue from controller to motor? Looks like The main Green and White stay Hot at 48v

Are the green and blue grounds?

http://www.fsip.biz/Documents/Club%2...leshooting.pdf

The test procedure I went through. All checked out accept MCOR BLK/WHT 2.1V and yellow to purple went from 1 to 4.5 then started jumping around. 9, 13, 3, 12, 8, 5, then.....1.0 Voltmeter error, I think..
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Unread 12-15-2014, 07:41 AM   #80
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Default Re: Couple of wiring questions.

Your new readings on the MCOR now correctly reflects how they fail.

As the wiper moves over a section that is oxidized, it looses connectivity and You get an open circuit.
That is the reason earlier I asked you to move the pedal up and down several times as You can sometimes "blast off" or "rub off" the oxidation.

You are again over thinking by testing a circuit that is not energized. The M- (6 gauge white wire), is like a ON/OFF switch to pack negative.
When the switch is OFF and You put the meter on that wire, You are actually reading the B+ voltage across the motor armature winding.
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