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01-14-2019, 11:04 PM | #1 |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
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Controller Lockout with OBC Bypass
Lots of people end up ditching OBCs in favor of smart chargers and some of them are only 2 wire hook-ups. Simple enough.
But some like the Lester Summit II can provide a lockout control circuit which seems like it can be connected if the user so desires. I’m sure this will vary by controller, but taking the Summit II for example, if configured for off-board usage, when it senses battery voltage on the charge pins (DC cord plugged into the cart), it then pulls the lockout circuit “low”. Ground? How can/should this then be connected to the controller to activate the lockout during charging? In the typical CC 3 pin receptacle the grey wire is already there, and runs back to near the controller. Seems like it should be fairly easy to use tha existing wire to either ground the controller lockout pin, or provide power to it via relay if that’s what’s necessary. Assuming the wire isn’t damaged and the in-line fuse is not blown. |
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01-15-2019, 06:56 AM | #2 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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Re: Controller Lockout with OBC Bypass
We have several threads for specific non-club car charger lockout implementations depending on on-board, external, Sepex, Series, Curtis or Alltrax controller combination.
For any external charger, the 3rd pin (aka: sense pin) should be connected to negative inside the charger or directly at the 3-pin plug. The Sepex are the easiest since we are dealing with logic level currents (milliamp). All you need is a 10kΩ x 1watt pull-up resistor on the Controller lockout pin. For Series carts (or alternative for Sepex) You will need a 48v N.C. relay with the coil connected between the KSI and the "sense" wire so you don't create a parasitic load on the cart while the charger is plugged but you disable the cart if the KSI is turned ON. This setup also prevents a regular PowerDrive type charger from working if plugged into the cart (for safety). |
01-15-2019, 10:47 AM | #3 |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
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Re: Controller Lockout with OBC Bypass
So for a sepex controller pulling the lockout pin to ground activates the lockout?
What is the pull-up resistor used for? Does the pin need pack voltage to then de-activate the lockout? |
01-15-2019, 10:54 AM | #4 | |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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Re: Controller Lockout with OBC Bypass
Quote:
http://www.buggiesgonewild.com/extre...ml#post1322529 |
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01-15-2019, 12:44 PM | #5 |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
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Re: Controller Lockout with OBC Bypass
Thanks Sergio! I think I got it now...
In the case of the Summit II at least, there is already a 10kohm resistor installed the charger from the Charge + lead to the interlock lead. Which is good for on-board use since you can then connect the interlock wire directly to the controller with nothing else required. Configured for On-board use, the charger activates the interlock only when AC power is supplied. For off-board use the charger activates the interlock when B+ voltage is present on the charge lead. But the resistor is no use for the interlock on the controller. It still needs input on the cart side to operate properly after the charger DC cord is unplugged. So it seems it's dependent on the controller being used, but Most should need a B+ input to the interlock pin on the controller to De-activate the lockout. Grounding the pin Activates it. So somewhere between the charge receptacle and the controller a 10kohm resistor is installed between the controller interlock pin and either KSI or some other B+ supply. And this will be the same regardless of which charger is being used. Then controllers without an interlock function, you would just interrupt the KSI via relay. Just wanted to make sure I have this right. Have a customer who wants a smart charger and asked me for suggestions, and they did ask specifically about the interlock function (presumably to keep the grand kids from trying to drag the charger out of the garage). |
01-15-2019, 01:02 PM | #6 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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Re: Controller Lockout with OBC Bypass
As far as I know the Summit does not come with a built in "pull-up" resistor, it needs to be added and it is not needed for onboard use with a Curtis Controller.
On the Curtis Sepex Controllers: IQ, Excel and ERIC, a "high" signal (pack voltage) on the Controller lockout pin is needed for the Controller to operate. The absence of a "high" signal, which means either connect the Controller interlock pin to negative or leave it disconnected (floating) activates the interlock and prevents the controller from working. If You are using an external charger and by-passing the OBC, instead of just connecting the Blue and White wires together which will disable the interlock, just add the pull-up resistor to keep the interlock pin "high" when the charger is not plugged. 10kΩ Resistor: https://www.mouser.com/ProductDetail...zOC9bCL9VxU%3d |
01-15-2019, 01:17 PM | #7 | |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
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Re: Controller Lockout with OBC Bypass
This is from the Summit II manual. Sounds like it has the 10k resistor built in.
But as I said, doesn't do any good for off-board use. Just simplifies the installation for on-board use. Quote:
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01-15-2019, 01:40 PM | #8 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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Re: Controller Lockout with OBC Bypass
As long as You understand how it works, it is just a matter of matching charger features and controllers needs, there are many possibilities and combinations.
Interesting the Summitt II 650W and 1050W are different on that aspect, the 1050W uses an external 10kΩ jumper (if needed). Summit II 1050w: https://lesterelectrical.com/wp-cont..._D.pdf#page=13 Summit II 650w: https://lesterelectrical.com/wp-cont..._D.pdf#page=14 If used onboard with a Curtis or Alltrax Sepex Controller, the pull up resistor is not needed since the controller just needs "full pack voltage" or nothing. |
01-15-2019, 03:24 PM | #9 |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
Posts: 8,987
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Re: Controller Lockout with OBC Bypass
I hadn't looked at the 1050w model, but that is interesting that it's different.
I see they also do not have the temp sensor lead input on the 1050w model. |
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