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Unread 11-06-2015, 04:37 PM   #31
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Default Re: Cart off - pre-charge resistor warm????

I had the same concerns after I did my conversion. Resistor gets real warm ...I can hold my hand on it, but it was uncomfortable. When I called Scotty I was assured it was normal behavior and it was only consuming very low amounts of energy to keep the controller precharged for longer life. I verified the low consumption by leaving my voltmeter on the charged and rested pack overnight and it didn't drop even a tenth of a volt. I couldn't be happier with that conversion kit.

Is your cart running as it should and your only concern is that the precharge is hot?
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Unread 11-06-2015, 05:36 PM   #32
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Default Re: Cart off - pre-charge resistor warm????

I just had a cart in here the other day with the 700Amp FSIP controller on it. Same situation. Warm resistor, but was working perfectly.
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Unread 11-06-2015, 11:09 PM   #33
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Default Re: Cart off - pre-charge resistor warm????

I had this idea earlier, but then I realized that in practicality You can improve the circuit for free (of course I thought of using a relay first).

If You assume the worst case: The capacitors are bad and shorted directly to ground, a maximum of 0.1 amps will ever flow through the capacitors: I=V/R (48v/470Ω=0.1A).

So If you disconnect the side of the pre-charge resistor connected to the pack positive side of the solenoid and instead connect it to the cold side of the Key Switch, You will have 0 amps when the Key switch is off, and no more than 0.1 amps load added to the key switch to keep the capacitors fully loaded.

I don't see any reason not to modify the circuit and power the pre-charge resistor from the key switch, thoughts?
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Unread 11-06-2015, 11:29 PM   #34
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Default Re: Cart off - pre-charge resistor warm????

I always flip the tow/run when I park it and plug in the charger that does the same to that resistor right?
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Unread 11-06-2015, 11:35 PM   #35
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Default Re: Cart off - pre-charge resistor warm????

No, the resistor is typically connected to the big post that goes directly to the pack positive cable.
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Unread 11-06-2015, 11:46 PM   #36
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Default Re: Cart off - pre-charge resistor warm????

Sergio I think you could precharge from the key switch. My only concern would for the initial start up but what the heck, 1 hard start is better than 20 in a day.
Not sure of the draw we are talking about here. Is there a simple way he can measure it so we know if it's really worth worrying about?
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Unread 11-06-2015, 11:55 PM   #37
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Default Re: Cart off - pre-charge resistor warm????

The worst case scenario, the current could not exceed 100mA, if the resistor is hot when the Key switch is off, I would think the current is way more than 0mA
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Unread 11-07-2015, 12:18 AM   #38
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Default Re: Cart off - pre-charge resistor warm????

Okay - I should have guessed as much.
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Unread 11-07-2015, 07:54 AM   #39
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Default Re: Cart off - pre-charge resistor warm????

I know it isn't drawing much but right now I have a voltmeter and the converter attached to the key switch, I really don't like the way it is set up, I need a terminal strip with all of the items landed there and bring back one wire to the key switch. That would be my only drawback. The capacitors charge and discharge rapidly so they are used to that, I can't see where the life expectancy would be much difference or would that be harder on them?
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Unread 11-07-2015, 09:17 AM   #40
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Default Re: Cart off - pre-charge resistor warm????

93yellowclubcar answered the question of the current draw on the 3rd post when he gave us the voltage drop across the pre-charge resistor, that works out to a little less than 50mA.

On the Sepex systems, the Controller usually does not release the solenoid until the cart is stopped (regardless of pedal position), so the capacitors are always charged on the solenoid contacts open.

Most of the Series systems the pedal directly controls the solenoid, so anytime the solenoid opens, the pre-charge resistor has to provide the capacitors charge current.

The 470Ω resistor will limit that current to no more than 100mA, and as Scooterman said, the capacitors are designed for that charge/discharge cycle already.

I know 50mA does not seem like much, but it is several times the self-discharge current of the pack, and since We are only introducing one additional capacitor charge cycle when the Key Switch is first turned ON, I think running the pre-charge resistor from the Key Switch is an easy way to eliminate the parasitic current on these FSIP Controllers.
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