Increasing the speed of a Series Motor

Sergio · 08-10-2015, 05:31 PM

Yes, it does require a separate solenoid of 200 (or more) amps and a few feet of 6ga cable to connect to the Motor S1 and S2 posts.

This particular implementation will reduce the Solenoid "break" current, which is the most damaging kind, to almost zero since it is deactivate by pedal up.

If you don't use the $5 relay in the design, You should consider a Solenoid with magnetic blowouts.

Your best gains will likely be realized on flat pavement as with the increase in speed there is a decrease in motor torque.

timmyjane · 08-10-2015, 05:51 PM

I think that I will follow your design and include one remote LED with inline limiting resistor.

Any thoughts on wiring in this led as it is 12v?

Amazon Link

Sergio · 08-10-2015, 08:24 PM

To use a LED as the latching diode, you cannot have any current limiting resistors.

The relay coil will limit the current to 20ma, which is the ideal LED current.

You could also have several LEDs in series since once the relay latches (full voltage with push-button), it only takes about 16v to keep it latched.

You can also use a momentary switch with a built-in LED, just make sure the resistor is either external (so it can be removed), or the switch says 3v for the LED.

Here are 2 samples I just saw on amazon, they have many sizes and color variations.

Blue ring switch

Green switch

I am not recommending anyone to build these "overdrive" circuits, this is just an idea on how to eliminate some issues with just a plain switch.

timmyjane · 08-10-2015, 08:29 PM

Cool. Thanks. That all makes sense. Seems that some folks have been successful with field weakening and with a little common sense this mod can be used safely.

timmyjane · 08-10-2015, 08:37 PM

Could the diode be moved to in front of the LEDs instead of after?

Sergio · 08-10-2015, 08:50 PM

The diodes D1 and D2 are supposed to be in parallel with each relay/solenoid coil.

They are also connected with reverse polarity so they will absorb the coil "fly-back" voltage when the relay/solenoid disengages.

That will save the Relay R1 contacts from arcing when the Solenoid disengages.

The only thing is that the LED will not come ON until You release the push button, even though the Solenoid will engage as soon as the push button is pressed.

theboss20 · 08-10-2015, 10:22 PM

What voltage would the new solenoid need to be?

Sergio · 08-11-2015, 06:22 AM

Both the Solenoid and the Relay are 48v coils.

I would also mount it a couple of feet away from the motor and use 6ga cables.

If You accidentally use the "overdrive" in a torque condition, the cables will get warm due to high current and might allow more current through the parallel field coil.

radelon · 06-22-2017, 01:31 PM

Quote:

Originally Posted by Sergio

Both the Solenoid and the Relay are 48v coils.

I would also mount it a couple of feet away from the motor and use 6ga cables.

If You accidentally use the "overdrive" in a torque condition, the cables will get warm due to high current and might allow more current through the parallel field coil.

Alright I've compiled a parts list from Mouser, the only thing I'm missing is the solenoid.

Mouser # Mfr. # Manufacturer Customer # Description RoHS Lifecycle Order Qty. Price (USD) Ext.: (USD)
1 655-T9AP1D52-48-01 T9AP1D52-48-01 TE Connectivity General Purpose Relays SPST-NO 30A 48VDC Relay Flange Mount RoHS Compliant 1 $4.57 $4.57
2 621-1N4007 1N4007-T Diodes Incorporated Rectifiers Vr/1000V Io/1A T/R RoHS Compliant By Exemption 1 $0.14 $0.14
3 941-C503BRCNCW0Z0AA1 C503B-RCN-CW0Z0AA1 Cree, Inc. Standard LEDs - Through Hole Red Round LED RoHS Compliant 1 $0.15 $0.15
4 941-C503BGCNCY0C0791 C503B-GCN-CY0C0791 Cree, Inc. Standard LEDs - Through Hole Green Round LED RoHS Compliant 3 $0.24 $0.72
5 941-C503BAANCY0B0251 C503B-AAN-CY0B0251 Cree, Inc. Standard LEDs - Through Hole Amber Round LED RoHS Compliant 1 $0.15 $0.15
6 621-1N4004 1N4004-T Diodes Incorporated Rectifiers Vr/400V Io/1A T/R RoHS Compliant By Exemption 1 $0.13 $0.13
7 612-PV5S64011 PV5S64011 E-Switch Pushbutton Switches Anti-Vandal PB Swch Off-(On) blk-blk RoHS Compliant 1 $4.59 $4.59

Does this look right? Did anyone ever have succes with this?

Sergio · 06-22-2017, 05:19 PM

Do You have a 36v or 48v cart?

I thought from the motor and the year of the cart in Your other thread that you are running a 5 Solenoid 36v cart.

http://www.buggiesgonewild.com/elect...-question.html

Here is another thread where a lot of people have done the "Go Fast" button and more related information:

http://www.buggiesgonewild.com/elect...st-button.html

Post your cart voltage and I will add more details.

08-10-2015, 05:31 PM	#11
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Increasing the speed of a Series Motor Yes, it does require a separate solenoid of 200 (or more) amps and a few feet of 6ga cable to connect to the Motor S1 and S2 posts. This particular implementation will reduce the Solenoid "break" current, which is the most damaging kind, to almost zero since it is deactivate by pedal up. If you don't use the $5 relay in the design, You should consider a Solenoid with magnetic blowouts. Your best gains will likely be realized on flat pavement as with the increase in speed there is a decrease in motor torque.

08-10-2015, 05:51 PM	#12
timmyjane Gone Wild Join Date: Jul 2015 Location: Simpsonville, SC Posts: 245	Re: Increasing the speed of a Series Motor I think that I will follow your design and include one remote LED with inline limiting resistor. Any thoughts on wiring in this led as it is 12v? Amazon Link Amazon Link

08-10-2015, 08:24 PM	#13
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Increasing the speed of a Series Motor To use a LED as the latching diode, you cannot have any current limiting resistors. The relay coil will limit the current to 20ma, which is the ideal LED current. You could also have several LEDs in series since once the relay latches (full voltage with push-button), it only takes about 16v to keep it latched. You can also use a momentary switch with a built-in LED, just make sure the resistor is either external (so it can be removed), or the switch says 3v for the LED. Here are 2 samples I just saw on amazon, they have many sizes and color variations. Blue ring switch Blue ring switch Green switch Green switch I am not recommending anyone to build these "overdrive" circuits, this is just an idea on how to eliminate some issues with just a plain switch.

08-10-2015, 08:29 PM	#14
timmyjane Gone Wild Join Date: Jul 2015 Location: Simpsonville, SC Posts: 245	Re: Increasing the speed of a Series Motor Cool. Thanks. That all makes sense. Seems that some folks have been successful with field weakening and with a little common sense this mod can be used safely.

08-10-2015, 08:37 PM	#15
timmyjane Gone Wild Join Date: Jul 2015 Location: Simpsonville, SC Posts: 245	Re: Increasing the speed of a Series Motor Could the diode be moved to in front of the LEDs instead of after?

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08-10-2015, 08:50 PM	#16
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Increasing the speed of a Series Motor The diodes D1 and D2 are supposed to be in parallel with each relay/solenoid coil. They are also connected with reverse polarity so they will absorb the coil "fly-back" voltage when the relay/solenoid disengages. That will save the Relay R1 contacts from arcing when the Solenoid disengages. The only thing is that the LED will not come ON until You release the push button, even though the Solenoid will engage as soon as the push button is pressed.

08-10-2015, 10:22 PM	#17
theboss20 Gone Wild Join Date: Jun 2014 Location: Green Valley, Az Posts: 678	Re: Increasing the speed of a Series Motor What voltage would the new solenoid need to be?

08-11-2015, 06:22 AM	#18
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Increasing the speed of a Series Motor Both the Solenoid and the Relay are 48v coils. I would also mount it a couple of feet away from the motor and use 6ga cables. If You accidentally use the "overdrive" in a torque condition, the cables will get warm due to high current and might allow more current through the parallel field coil.

06-22-2017, 05:19 PM	#20
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Increasing the speed of a Series Motor Do You have a 36v or 48v cart? I thought from the motor and the year of the cart in Your other thread that you are running a 5 Solenoid 36v cart. http://www.buggiesgonewild.com/elect...-question.html Here is another thread where a lot of people have done the "Go Fast" button and more related information: http://www.buggiesgonewild.com/elect...st-button.html Post your cart voltage and I will add more details.

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