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Unread 02-20-2015, 01:57 PM   #1
Not Yet Wild
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Default 5k-0k Throttle to 0k-5k Throttle???

1998 Club Car DS Series

I have been researching controllers for my cart. I know Alltrax, GE (FSIP) and Curtis are the main GOLF CART CONTROLLERS. But I have found that the EV world is much broader. Kelly controllers have supposedly came a long way in the last few years and are popular with the EV car and bike crowd. All the Kelly controllers are 0k-5k (2 wire), 0v-5v (3 wire, <100k can work), or 1v-4v Hall Effect throttle input.

I found this in an old thread on this site. "0-5K can be made into a 5k-0 by simply swapping the outer two wires on a 3 wire pot or by changing the outer tap point on a 2 wire pot."

I wonder could one reverse the wiring on a 5k-0k pot to make 0k-5k to feed a Kelly controller? If not, what would I have to do to my CC to provide the correct signal with out gutting the pot box and installing an EV type throttle. The Kelly controller price is very lucrative and they provide software as well (free). I'm wanting to go 500A-800A and that gets PRICEY with the name brands. Amps are amps... And I want as many as I can get for the lowest price!

Thanks!
CT
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Unread 02-20-2015, 02:13 PM   #2
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

There is no such thing as a 5kΩ-0 club car pot.

You either have a 3 wire Multi-step Potentiometer (Vglide body) or a 3 wire Continuously Variable Potentiometer.

Either one can be used for 0-5kΩ, 5kΩ-0 or 0-5v.

Let us know how the Kelly controller works.
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Unread 02-20-2015, 03:02 PM   #3
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

What price ranges are you seeing
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Unread 02-20-2015, 03:33 PM   #4
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

If Kelly made as good a golf cart control as Alltrax don't you think their name would be a little more prevalent?

My information tells me they do not make a reliable golf cart control.
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Unread 02-20-2015, 03:34 PM   #5
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

Quote:
Originally Posted by Sergio View Post
There is no such thing as a 5kΩ-0 club car pot.

You either have a 3 wire Multi-step Potentiometer (Vglide body) or a 3 wire Continuously Variable Potentiometer.

Either one can be used for 0-5kΩ, 5kΩ-0 or 0-5v.

Let us know how the Kelly controller works.
Pardon my ignorance... From what I have read, all Club Car's after 1995 or 1996 the throttle input is 5KΩ-0Ω. The earlier were V-Glide or 0Ω-5kΩ... My CC has the black "GO" pedal that is linked to a black, wedge shaped box under the drivers seat area. I'm leaning towards the 3 wire pot is what is under the cover.

Soooooo..... I was trying to save the step of me pulling out the Fluke 187 and ohming out the pot box (its cold outside!) If it is in fact 0Ω-5kΩ this is GREAT. I know enough about industrial analog controls (I am a Controls Engineer) to be dangerous. I just have not dug very deep into how the GO pedal make the controller output. If in fact its just a pot, I can make this work.

CT
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Unread 02-20-2015, 03:50 PM   #6
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

I have seen that comment about "all Club Car's after 1995 or 1996 the throttle input is 5KΩ-0Ω."

My best guess how that has come about is that when you test the series controller and measure the resistance from pin #2 to Pin #3, You get 5kΩ-0 swing.

That is just a test, the Controller actually works on a 0v-5v. If You disconnect the Low side of the pot, it will not work regardless of the resistance You are measuring.

As You know with a 3 wire potentiometer (not a 2 wire rheostat), the resistance range is a matter of which side of the potentiometer is your reference for the wiper.

If You see 5 wires going to that pie shape box (2 for micro switch a 3 for the pot), then it is a 5kΩ potentiometer and it can have a range go up or down.

If You only have 4 wires (2 for the micro switch and 2 for the pot), then it is a 5kΩ rheostat and it is factory wired to have a 0-5kΩ range. The range can only be changed by moving the wires to a different pad on the Multi-Step Potentiometer, which is a simple procedure.
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Unread 02-20-2015, 03:55 PM   #7
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

Quote:
Originally Posted by greg-g View Post
What price ranges are you seeing
KDZ48650 $369 24v-48v 650A 1 min 260A cont

KDZ72650 $479 24v-72v 650A 1 min 260A cont

KDH72800D $599 24v-72v 800A 1 min 360A cont
This model series is Opto-Isolated. The control side requires 12v@200mA. It is optically separated from the main pack voltage. This is fine, I have a 12V aux battery anyway with an onboard charger for accessories.

They have drives up to 156V Also they have series drives that can REGEN! Don't know if I really need that for a golf cart. But could be advantageous in an EV with a brushed or PM motor.

CT
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Unread 02-20-2015, 03:59 PM   #8
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

Quote:
Originally Posted by Sergio View Post
I have seen that comment about "all Club Car's after 1995 or 1996 the throttle input is 5KΩ-0Ω."

My best guess how that has come about is that when you test the series controller and measure the resistance from pin #2 to Pin #3, You get 5kΩ-0 swing.

That is just a test, the Controller actually works on a 0v-5v. If You disconnect the Low side of the pot, it will not work regardless of the resistance You are measuring.

As You know with a 3 wire potentiometer (not a 2 wire rheostat), the resistance range is a matter of which side of the potentiometer is your reference for the wiper.

If You see 5 wires going to that pie shape box (2 for micro switch a 3 for the pot), then it is a 5kΩ potentiometer and it can have a range go up or down.

If You only have 4 wires (2 for the micro switch and 2 for the pot), then it is a 5kΩ rheostat and it is factory wired to have a 0-5kΩ range. The range can only be changed by moving the wires to a different pad on the Multi-Step Potentiometer, which is a simple procedure.
Without pulling the cover, this is what I assumed is going on. Usually analog control signals are 4-20 mA or 0-5v, 0-10v, or bipolar -5-5v... Sounds like I can keep the stock pot and make this work.

CT
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Unread 02-20-2015, 04:14 PM   #9
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

Quote:
Originally Posted by scottyb View Post
If Kelly made as good a golf cart control as Alltrax don't you think their name would be a little more prevalent?

My information tells me they do not make a reliable golf cart control.
scottyb...


If Kelly made as good a golf cart control as Alltrax don't you think their name would be a little more prevalent? I don't know if this is factual or not.

I just started reading about them last night. They are manufactured in China and sold through a company in the US. The screen shots of the software and the overall appearance of the drives make me wonder if they reverse engineered Curtis drives. I had never seen their name come up on the BuggiesGoneWild forums, but came across them on some DYI EV forums. They make drives up to 1800A@120V down to 50A@12V. Some drives even support 144V and 156V. This is serious power levels!

For the price of their 650A-800A drives, I can take the savings and put it towards other go fast and make gobs of torque parts.

CT
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Unread 02-20-2015, 06:19 PM   #10
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Default Re: 5k-0k Throttle to 0k-5k Throttle???

Try them (at your own risk) since nobody here has any experience with them.
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