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Old 03-11-2014, 12:04 PM   #1
criley
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Default About controllers

Looking at the manual I have, the controllers (both DCS and non-DCS) are just black boxes, and there's not much info in regards to how they work.

I'm one of those guys who has to know how stuff works. It's a failing of mine.

Concentrating on a series motor ('cause that's the kind in my cart), I'm guessing that the controller is just doing some kind of pulse width modulation to control the speed of the motor?

Anyone got links where I can go to learn more about this?

The thing I don't like about the controllers I've been looking at is that they don't seem to be serviceable. If a power transistor fails or something, you have to replace the whole controller vs. an inexpensive part. I can't help it. I'm cheap.
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Old 03-11-2014, 12:44 PM   #2
Sir Nuke
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Default Re: About controllers

Your are right, what you are looking at, the black box, is a stock controller and is not serviceable. Now as far as how they really work, you need to talk to JohnnieB.
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Old 03-11-2014, 05:03 PM   #3
sportcoupe
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Default Re: About controllers

Stock ezgo controllers can be rebuilt. See link for models and pricing.

http://www.capsservice.com/
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Old 03-12-2014, 07:18 AM   #4
criley
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Default Re: About controllers

Quote:
Originally Posted by sportcoupe View Post
Stock ezgo controllers can be rebuilt. See link for models and pricing.

http://www.capsservice.com/
Wow, thanks for the link!
I haven't taken mine off yet, I guess I just assumed it was filled with epoxy.

So ezgo must use a curtis controller. I will see if I can find schematics on that.
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Old 03-12-2014, 10:38 AM   #5
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Default Re: About controllers

In case anyone is interested, I think I have found the Curtis manual for the series controller. Attaching it.

There's some theory and specifications on the last two pages. Also interesting reading for anyone contemplating replacing the f/r switch with a contactor (which appears to be what Curtis recommends).
Attached Files
File Type: pdf (Curtis COntroller Manual) 1204_05.pdf (478.7 KB, 0 views)
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Old 03-12-2014, 03:40 PM   #6
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Default Re: About controllers

Ok experts - I found an open source, programmable series motor controller that is rated for up to 144 volts and 1000 amps. You can buy the parts and build it yourself for about 350, or buy a kit with everything together (including milled/etched circuit board) for around 600 (still have to build it, but don't have to shop for parts or have any fabrication done).

Series carts only I'm afraid.

Here's the thing - there's no a2 connection.

If I understand correctly, that connection is used solely for plug braking, which only comes into play if you were to switch from forward to reverse (or visa versa) while the cart is moving.

So if I am willing to accept the fact that if I don't stop before changing directions I will be launched like the Apollo moon rocket, the lack of a2 (and plug braking) is a non-issue.

Seriously thinking about putting one of these together.

Open ReVolt
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Old 03-12-2014, 05:49 PM   #7
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Default Re: About controllers

That's interesting. It would certainly fit into the category of "flexible use". But I question why you would want or need anything that big. What are your future plans for the cart?
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Old 03-12-2014, 07:20 PM   #8
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Default Re: About controllers

Quote:

There's some theory and specifications on the last two pages. Also interesting reading for anyone contemplating replacing the f/r switch with a contactor (which appears to be what Curtis recommends).
criley,
I completely rewired an old Club Car, using scrapyard parts: a Curtis controller, pot box, solenoid, and F/R contactor. Stuff came from old golf carts, a Cushman electric truck, and an electric pallet jack. The latter furnished the contactor; it had 24 volt coils, so I installed a resistor so it'd operate from the 36 volt pack.

During all my research, I ran across a site that had a description on upgrading a Curtis controller for more current capability, but don't remember the details. It seems to me that a 1204/5 could be used to drive a heavier-duty output section, but I'm not enough of an expert to be able to design such a thing.
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Old 03-12-2014, 07:39 PM   #9
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Default Re: About controllers

Quote:
Originally Posted by criley View Post
Ok experts - I found an open source, programmable series motor controller that is rated for up to 144 volts and 1000 amps. You can buy the parts and build it yourself for about 350, or buy a kit with everything together (including milled/etched circuit board) for around 600 (still have to build it, but don't have to shop for parts or have any fabrication done).
You can buy an Alltrax 72450 for $400, it can accept up to 72v and is 450 amps. It has a warranty also. Series motors too.

The only reason you'd want 144v is drag racing with agm type batteries I believe. What are your goals?
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Old 03-13-2014, 08:02 PM   #10
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Default Re: About controllers

I don't ever see myself going to a 144 volt pack. 48 probably, and maybe (probably) a motor upgrade. This controller would definitely handle that. You should see the buss bars on this thing! Definitely worthy of 2ga welding wire.

As I'm contemplating cart upgrades, in the back of my mind I keep thinking about the TRS-80 computer I bought when I was about 15. I only got it with 4k of ram, 'cause there was no way I'd ever use 16k!
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