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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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03-11-2014, 12:04 PM | #1 |
Not Yet Wild
Join Date: Jan 2014
Location: South Carolina
Posts: 44
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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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03-11-2014, 12:44 PM | #2 |
Master of All Things
Join Date: May 2013
Location: West Columbia, Texas
Posts: 17,863
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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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03-11-2014, 05:03 PM | #3 |
Gone Wild
Join Date: Sep 2012
Location: Savannah, GA
Posts: 2,760
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Re: About controllers
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03-12-2014, 07:18 AM | #4 | |
Not Yet Wild
Join Date: Jan 2014
Location: South Carolina
Posts: 44
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Re: About controllers
Quote:
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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03-12-2014, 10:38 AM | #5 |
Not Yet Wild
Join Date: Jan 2014
Location: South Carolina
Posts: 44
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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). |
03-12-2014, 03:40 PM | #6 |
Not Yet Wild
Join Date: Jan 2014
Location: South Carolina
Posts: 44
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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 |
03-12-2014, 05:49 PM | #7 |
Gone Wild
Join Date: Aug 2011
Location: Central Delaware
Posts: 859
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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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03-12-2014, 07:20 PM | #8 | |
Gone Wild
Join Date: Nov 2010
Location: Lower SE Michigan
Posts: 330
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Re: About controllers
Quote:
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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03-12-2014, 07:39 PM | #9 | |
Gone Wild
Join Date: Sep 2012
Location: Savannah, GA
Posts: 2,760
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Re: About controllers
Quote:
The only reason you'd want 144v is drag racing with agm type batteries I believe. What are your goals? |
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03-13-2014, 08:02 PM | #10 |
Not Yet Wild
Join Date: Jan 2014
Location: South Carolina
Posts: 44
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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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