Any issue hooking the key switch directly to the Solinoid?

Dlab

2001 36 volt DS that I converted to solid state 48 volt via ScottyB. The micro switch on the pot had the solinoid constantly clicking on and off, and sometimes shutting down completely until I wiggled it.

Looking at the original diagram I just hooked the key switch wire directly to the solinoid, so I just have to turn the key to off when I stop to power off the system. It’s a hunting cart and this seems to be working perfectly as of right now. No more issues with it clicking on and off or shutting down. Would this cause any issues to leave it this way if I always turn the key off when I’m stopped?

Just wondering. I sent Scotty an email about a new micro switch and he sent it out within 10 minutes of payment! Now that’s customer service!

But I’m currently at the camp hunting and won’t be home to get the new micro switch.

I actually like it better this way, less clicking while in the woods. I can put the HD F/R in the position I want then turn the key and take off without 2 loud clicks.

BGW

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scottyb

If the solenoid and/or the reversing contactor is not clicking when the gas pedal is depressed then they are already engaged/activated - in which case they could easily exceed their duty rating causing them to prematurely fail.

Dlab

Scotty, the way I have it now the Solinoid clicks when I turn the key ON. The reversing contractor then still clicks from F/N/R as the system is powered ON when the key is ON. Just essentially bypassing the micro switch you sent me. When I stop I turn the key OFF, and the solinoid clicks off. Seems to be doing as it’s supposed to, just not pedal activated by the micro.

scottyb

That's fine so long as you don't lend the cart or forget and leave the key on overnight.

DaveTM

Just me, but I'd wire it so the solenoid isn't always engaged when the key is one. Your going to have premature failure as there are only so many "clicks" (contacts) that piece of equipment will do. There is some heat when the contacts are made.....and heat will cause failure at some point.

Fairtax4me

By that logic it would click less, since it's not clicking every time the pedal is pushed.


Only issue I can see is if the Reversing Contactor is getting power sent to it all the time, it may eventually arc and burn the contacts in the RC. When the solenoid opens there is no power at the contacts in the RC. If the solenoid is always closed, then the RC is switching contacts while there is power applied on the contacts. It might take a while to cause any harm, or it might make no difference at all, but that's the only issue I can see other than what ScottyB said, don't forget to turn the key off.

DaveTM

I had the word (CONTACTS) in parenthesis. I would think with the solenoid being constantly closed and powered, it just ain't gonna last as long.

But that's what I think. That's my LOGIC.

Fairtax4me

Not trying to call you out or anything man, just wasn't clear to me what you were saying. This forum's about overdue for a useless debate anyway...

These solenoids are designed for at or near 100% duty cycle, they stay engaged as long as you have your foot on the pedal anyway, so having it close with the key switch (vs the pedal switch) really shouldn't make a huge difference in life span. Assuming that at some point after riding for several hours the key switch does get turned off. I suppose if it gets left on for months straight, maybe that could shorten the coils "time-life".
The contacts are usually rated for X,000,000 number of closings before they wear out, so I'd suppose that having it constantly powered would extend the "time-life" of the contacts.

But like I said before, I'd be more concerned with whats down the line in the flow of electricity. The Reversing contactor costs more than a solenoid, and I would worry that the contacts in that might be eventually damaged by switching while still having voltage applied.

scottyb

I had a dealer buying contactors from me and he had one burn out so I replaced it. Then he had another burn out so I replaced it. Then - yeah... So I asked if all the reversing contactor failed in the same direction... guess what? Yeah, turned out the guys customer was backing the cart into a shed and leaving the contactor engaged overnight. All units failed in reverse.

DaveTM

Again.....not an engineer, but I can only assume that the solenoid and it's open\close contacts are made for a reason. If it were not necessary to have a solenoid, then just wire it direct.