lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car
Electric Club Car Electric DS, and Precedent golf cars



Post New Thread  Reply
 
Thread Tools Display Modes
Old 01-08-2017, 01:28 PM   #21
Golferdave
Gone Wild
 
Golferdave's Avatar
Club Car
 
Join Date: Dec 2016
Location: Alaska/SoCal
Posts: 549
Default Re: Tinned Copper cables or not

Electrical solder 60/40 (tin/lead) with a melting temp, 400° F.
Some lead free electrical solder , with higher % of tin
When "tinning" wires, do it quick so not to wick the solder up the wire,
it makes the wire stiff
We had an "anti wicking " tool to prevent that,


Plumbing solder is not electrical solder
Some is acid core
All now is "no lead"
Golferdave is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 01-08-2017, 02:23 PM   #22
JohnnieB
Techno-Nerd
 
JohnnieB's Avatar
E-Z-GO
 
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
Default Re: Tinned Copper cables or not

I've never put a scope on the output or input to a golf cart motor controller, so I stole the wavshape drawing from the Curtis 1204/1205 manual.

Here is the whole page as well as a page with a block diagram for a 1204/5 controller.

From what I can tell, the power output section of the controllers we have today is roughly the same as it was in the 1204. Probably some improvements in the components themselves, but I believe the block diagram and theory of operation are about the same. There have been big changes in the logic circuits controlling the power output section, but the basic functions are still about the same in those areas also.

The part I find fascinating is the "Freewheel" diode (aka Flyback), which allows current to keep flowing in the same direction through the windings when the MOSFETs turn off. This turns the energy stored in the inductance of the windings into torque rather than being lost as heat, increasing the motor's efficiency at duty cycles less than 100%.

What isn't shown or mentioned, is that this also means the motor current is higher than the battery current when the duty cycle is less than 100%, which in turn means the amp flow is higher between controller and motor than it is between controller and battery unless duty cycle is 0% or 100%.

That in turn means that the cable from the motor to B+ should be connected to the B+ terminal on the controller instead of the controller side large terminal on the solenoid, to keep the current pact (cable length) as short as possible. I don't know about CC or other brand carts, but EZGO connected the B+ cable from motor to the solenoid's controller side large terminal along with a short cable to the B+ terminal on the controller when both of those cables ought to have been connected to the B+ terminal on the controller.

-------
FWIW: A SepEx controller works about the same as a Series. A Series controller has a single set of high power MOSFETs while the SepEx controller has three sets, one high power set feeding the armature and two low power sets feeding the field (one set for Forward and another one for Reverse). Of course the logic section of a SepEx controller is more complex.
Attached Images
File Type: jpg PWM waveshape at motor.JPG (182.4 KB, 0 views)
File Type: jpg Curtis 1204 block diagram with text.jpg (186.6 KB, 0 views)
JohnnieB is offline   Reply With Quote
Old 01-08-2017, 04:31 PM   #23
crash test dummy
Guest
 
Posts: n/a
Default Re: Tinned Copper cables or not

well there you go !!!
thanks johnnie
  Reply With Quote
Old 01-08-2017, 06:05 PM   #24
Muddog
Crazy Wild
 
Muddog's Avatar
Club Car
 
Join Date: Jun 2015
Location: Carolina Lowcountry
Posts: 796
Default Re: Tinned Copper cables or not

My thoughts exactly.
Thank you ,JohnnieB
Muddog is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car


Thread Tools
Display Modes


Similar Threads
Thread Forum
1/0 5/16" Tinned Copper Cable Lugs Golf Carts and Parts
Copper contacts Electric EZGO
solid copper for battery cables? Electric Club Car
Tinned copper lugs? Electric EZGO


All times are GMT -5. The time now is 05:39 AM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.