Motor vs controller & controller programming

[Fidele castor]

Hello everyone,

I live in France and I own two golf carts EZGO TXT that I have often modified but I have some remaining problems to solve.

My first golf cart :

Motor :EZGO DCS & PDS REGEN- HIGHEST TORQUE Motor by D&D, 8.9 Peak HP, 3250 RPM, SPEED up to 14 mph, +40% more torque when used with the stock 36v controller. Used on REGEN EZGO DCS 1995'-1999' and PDS 2000'- (bought in 2015)

Controller : ALLTRAX XCT 500 AMP EZGO PDS SPEED CONTROLLER (bought in 201

Problem:
The speed regen control function is not working.
I also see this fault on the control software that is on my PC.
I suspect a motor speed sensor failure or a bad connection of the three wires coming out of the speed sensor.
What is the signal that must come out of these three wires ? Voltage? Frequency?
What is the right connection map of these three wires?



My 2nd golf cart :

Controller :
Sevcon PowerpaK SEM 24-48V 500A/50A model PP745

Problem :
The controller is currently running on 36V batteries and I would like to set it to work with 48V batteries.
I read that it would be possible to set it with a PC and a software.
Who could tell me the type of cable needed as well as the software to use and where to find it?

I hope you understand my writing in English and, in advance, I thank you for your answers !

Gerard

[JohnnieB]

Bienvenue chez BWG!

Hopefully, that is Welcome to BGW in french! I lived in Paris for a few years back in the mid-1960's, but never was very good with the language and have barely used it since then.

I can help you with the EZGO cart but not the other one.

Looks like you have a D&D 170-502-0001 motor and a XCT48500-PDS controller.


The speed sensor on the D&D motor has Black, Red and Green wires.
The EZGO speed sensor cable has Black, Red and White wires.
Connect Black to Black, Red to Red and Green to White.

Black is Negative (0V)
Red is Positive (Supplied by controller, typically from about 12V up to about 15V)
Green/White is the output signal from the speed sensor. (Pulsed DC, about 5V.)

Frequency is Four Pulses per motor revolution. Set XCT to 8-poles (four pairs of poles equals 8 poles -- one pulse per pair of poles)

[Fidele castor]

Thank’s A lot JohnnyB for this detailed answer.

Regarding the golfette n ° 1:

I checked the wiring again, it was ok.

Then I disconnected the red and black wires to check if, on the drive side, I have the 12V voltage which supplies the speed sensor:
I measured and I found - 48V between the red and the black!

This mean that there was + 48V between black and red !
So I get a reversed voltage and much higher than expected !

This measurement was checked both when the accelerator pedal is pressed and when it is not.

What do you think about it ?
What can I do now ?

[JohnnieB]

With the Black and Red wires at the motor disconnected from the Black and Red wires from the controller, your voltmeter is probably reading a phantom voltage. Reconnect the Black to Black and Red to Red, them measure the voltage between Black and Red.

The 12V ought to be present all the time, except when Run/Tow switch is in Tow. When cart is pushed or pull when in Run, the beep[er will sound and the regen brakes will be applied to limit cart to about 3.2kph.

Also. if you connect your voltmeter from Black wire to the White/Green wire, you should see a small voltage when cart is pushed.

[Fidele castor]

Originally Posted by JohnnieB

Reconnect the Black to Black and Red to Red, them measure the voltage between Black and Red.

Ok thanks,
That was done and now I get -1.24 V instead of 12V between red and black wires

[JohnnieB]

Since you were getting 12V between the black and red wires from the controller when they were disconnected from the speed sensor on the motor and only 1.2V when they are connected, I suspect the speed sensor is bad.

[Fidele castor]

Ok i think it must be something like this.

I’ll try to get a new one.

I wish you a happy new year.

[JohnnieB]

Bonne Année (If I remember correctly )

[mjroman20]

The Sevcon requires a program called PCpak, its only available from Sevcon/Borgwarner as far as I know. It also needs the PCPak dongle, again only from Sevcon.

FSIP may be able to reprogram the voltage ranges for you, but seeing as you're in France you could try TVH in Belgium; I know they work on some of those as well. If all else fails you could try Sevcon's UK office but they usually wont make changes like that without permission from the OEM; legal issues and whatnot.

[scottyb]

JohnnieB whispers sweet nothings in French to SWMBO