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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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Thread Tools | Display Modes |
02-12-2016, 03:17 PM | #11 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Controller upgrade
The 1k resistor does not stay connected to the cart. It is a simply a tool I use when I reconnect the last high current cable, or when I discharge the filter caps in the controller. (Or the capacitor in a battery charger)
If the cable(s) on the controller's B+ or B- terminals have been disconnected long enough for the filter capacitors to discharge, when you reconnect the last high current high current cable, you will get a spark when the cable end touches the terminal it is being connected to. Despite having a pre-charge resistor installed, if the filter caps are significantly discharged, you will get a spark. To reduce the intensity of the unavoidable spark, I use two generic jumper wires with alligator clips on the ends and clip a resistor between them. Then clip the other ends to the cable end and terminal it goes to. Electrically, I'm adding more resistance in series with the pre-charge resistor to further limit the inrush of current to the filter capacitors. During normal operation, the pre-charge resistor only has to cope with the filter capacitor bleed rate while the solenoid contacts are open. When the capacitor are fully discharged, the pre-charge resistor by itself will allow enough current flow to cause a visible spark. FWIW: A XCT-PDS controller like I now have, does not use a pre-charge resistor, it keeps the filter capacitors charged by other means. However, I used (when I remembered to do so) the clip leads and resistor routine when I was running a DCX controller. BTW, the cold resistance of a 60W 120V incandescent light bulb is about 13Ω while the hot resistance is about 240Ω. The pack voltage being less then 120V, the bulb will never reach its hot resistance value and even if it did, you would only be doubling the value of the pre-charge resistor, so the spark reduction wouldn't be as much as using a 1k or higher value resistor. |
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03-01-2016, 09:23 PM | #12 | |
Gone Wild
Join Date: Sep 2015
Posts: 572
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Re: Controller upgrade
Quote:
In any case, if I need a fuse for the main circuit, (500 amp controller) where do I get one? I checked a few sites and only found the 50-60 ones. |
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03-01-2016, 11:16 PM | #13 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,356
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Re: Controller upgrade
1. There are slow and long burning fuses. A long burn 400a fuse is plenty for a short burst of 600a -
2. These fuses are said to be designed for catastrophic event... Honestly I have seen the catastrophic event where the cart burned but the fuse did not. Secondly no other controller manufacture utilizes a fuse. You decide how crucial it is. |
03-02-2016, 08:28 AM | #14 |
Getting Wild
Join Date: Nov 2015
Location: Seattle,WA /Sebastian,FL
Posts: 106
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Re: Controller upgrade
One more time...
I installed a 400Amp ANN fuse for catastrophic events. All fuses and circuit breakers have a time/current data sheet to go with them, ie.. a 400amp fuse does not magically blow at 401 amps. Different types of fuses and breakers have a different delays before trip. I am attaching a example sheet for you viewing. Ahhh got the ANN data screen shot and data sheet attached. |
03-02-2016, 09:11 AM | #15 |
Gone Wild
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,119
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Re: Controller upgrade
My Alltrax controller (from Scottyb) came with a 400A fuse which I installed. From my extensive electronics experience, that fuse won't protect the controller from damage but it might keep the system from having a meltdown.
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03-02-2016, 09:30 AM | #16 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,356
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Re: Controller upgrade
These Alltrax controls have built in reverse polarity protection. DIYers have tested the design. I have seen the top blown off the super 400 solenoid when the main + and - were connected to solenoid mains. The controller and the fuse survived.
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03-02-2016, 10:00 AM | #17 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Controller upgrade
Fuses and Circuit Breakers are fire protection devices rather than equipment protection devices and they don't always prevent fires.
When I exploded a stock PDS motor a while back, it took out the DCX400 controller, but not the ANN250 fuse. Attached is a larger copy of the graph that rottie posted. The easiest one to see is the ANN800. It shows that the "Very Fast Acting" 800A fuse will pass about 1050A (130% of its rating) for about 100 seconds (1.67 Minutes). |
03-02-2016, 11:57 PM | #18 |
Getting Wild
Join Date: Mar 2012
Posts: 149
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Re: Controller upgrade
JohnnieB, Ive been searching threads for the XCT48500 (just got one today) setup but havent found much. Any chance you could take some pics of your wiring? Like where does the run/tow switch go? and the diode install etc
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03-03-2016, 12:35 AM | #19 |
Gone Wild
Join Date: Apr 2014
Location: Oregon City, Or
Posts: 1,977
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Re: Controller upgrade
Tip-- I've gotten in the habit of covering the battery bay with an old yoga mat, only exposing what's being worked on. Gotta keep those amps where they belong.
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03-03-2016, 10:24 AM | #20 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Controller upgrade
Quote:
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