Help with pre-charge resistor...

[itchynackers2]

Hello,
Long time follower, first time poster. I have a simple Chinese stand-up scooter running on 48 volts. Here is a link to a few pics of it... http://www.modifiedelectricscooters.com/forum/topic.asp?TOPIC_ID=865 I ordered the kelly kds48100 controller to hopefully help the performance. A pre-charge resistor and (I think) a couple of diodes came with the controller kit. I am a novice at best when it comes to electrical components. My question is, where do I wire in the pre-charge resistor? Where do I put the diodes (I don't think I have a coil driver). I've done a lot of reading on it, and it seems I should wire it across the "main contactor". I don't have a contactor (I think). I just have a keyed on/off switch which isn't on the main power circuit. Any help would be appreciated. Remember, I'm a first grader when it comes to electronics, so please explain in detail (any pics would also help).

Thanks!

Adam

 

[Lyen]

Hello,
Long time follower, first time poster. I have a simple Chinese stand-up scooter running on 48 volts. Here is a link to a few pics of it... http://www.modifiedelectricscooters.com/forum/topic.asp?TOPIC_ID=865 I ordered the kelly kds48100 controller to hopefully help the performance. A pre-charge resistor and (I think) a couple of diodes came with the controller kit. I am a novice at best when it comes to electrical components. My question is, where do I wire in the pre-charge resistor? Where do I put the diodes (I don't think I have a coil driver). I've done a lot of reading on it, and it seems I should wire it across the "main contactor". I don't have a contactor (I think). I just have a keyed on/off switch which isn't on the main power circuit. Any help would be appreciated. Remember, I'm a first grader when it comes to electronics, so please explain in detail (any pics would also help).

Thanks!

Adam

Hi Itchy! That is one of my favorite forum with my brushed motor equipped scooters. I've got 4 stand-up style scooter too! My favorite one is the FX1 purchased used from Deafscooter.
As to answer your questions, if the pre-charge resistor is used to prevent sparks then simply attach it to the positive lead between the battery and the controller. Once precharged, you need to bypass it before you turn the throttle to accelerate or the resistor will heat up and burned out.

How big is your diode(s)? Difference size serve a little different purpose. Please put the images of your diode here so we can tell.

 

[itchynackers2]

Ok, I believe I have the pre-charge figured out. But as to your question about the diodes. I'm looking at it and it says "IN5404" on it, and below that it says "MIC". I wasn't planning on using the diodes since I don't have a contactor or coil. I am having trouble hooking up the controller properly though.

I have a 4-wire lighted throttle (red,blue,green,yellow). The red,blue,green seem to be going to a microchip looking thing (hall sensor?) in the throttle. Then another wire comes out of where the blue wire went in and goes (along with the last yellow wire) to the lights on the throttle.

The last 3 wires seem to be coming from the 3 position key switch (off / on / on with headlight). Here is a pic of all 7 wires...

Here is a pic from the kelly kds48100 manual of the wiring ports...

I was able to program the controller using a 24Volt battery setup hooked to the red(9) wire and grounding it the the "B-" terminal on the other side of the contoller. I have an l.e.d. light plugged into the black(1) and brown(2) pins and it did light up showing a low voltage code (1 then 3 lights). I programmed the controller to:
Foot Switch---------------------Disable
Throttle Sensor Type---------5V-0 ( I measured the at rest voltage at 4.5V with the old controller hooked up)
Throttle effective starting position-----20%
Throttle effective ending position------80%
Max armature current---------------80%
Startup Delay Time----------------2 seconds
Main Contactor Hold Duty--------30%
Half Speed in Reverse------Disable
High Pedal--------Enable
Motor Top Speed------100%
Load Type-----------Median Load
Under Voltage-------46 Volts
Over Voltage--------56 Volts
Throttle Up/Down Rate-----5

I hope these settings are correct. Any help would be appreciated.

Thanks,

Adam

 

[itchynackers2]

Ok, I connected everything as Kelly recommended (I think) like this:

Junction1:
Red(9) ---> key switch--->battery +
Black(1)--->led--->brown(2)
Green(4) capped, no connection

Junction2:
White(5) capped, no connection
Black(10) capped, no connection
Orange(7)---->red on throttle
Blue(6)---->blue on throttle
Black(8)---->green on throttle

B+ --->main contactor(with resistor)---->battery positive
M ---->motor negative
B- ---->battery negative

When I switched on the key, I was able to get a solid red on the l.e.d. light. However, when the throttle was turned, nothing happened. I tried 2 other throttles, and got the same result. I even pulled out the throttle connections to Junction 2 and I still had a solid red light (no error codes). My controller settings are as follows:

General Setting
Foot Switch-----Disable
Throttle Sensor Type-----0-5V
Throttle Effective Start-----20%
Throttle Effective End-----80%
Maximum Armature Current-----100%

Startup Delay Time-----2 seconds
Main Contactor Hold Duty-----30%
Half Speed in Reverse-----Disable
High Pedal-----Enable

Motor top speed-----100%
Load Type-----Median Load
Under Voltage-----43Volts
Over Voltage-----56Volts
Throttle Up/Down Rate-----3

Also, I measured the voltage across the red and green wires on the throttle (at rest) and got 4.61V. I measured the voltage across the red and blue wires on the throttle (at rest) and got 3.98V. I measured the voltage across the blue and green wires on the throttle (at rest) and got 0.64V. I measured the voltage across B+ and B- and got 51V.

Not sure what to do next. I suspect I need to do something with those capped wires on Junction 2, but am unsure. Anybody see any problems here?

As a side note, I accidentally jumped across the red and blue leads (3.98V) on the throttle, and the tire spun about 10mph. I'm not sure if that is helpful or not.

Also, here is a pic of where the wires go into the throttle. Maybe someone can see if I'm doing something wrong.

Thanks,

Adam

 

[Metallover]

I had a similar problem with my bike throttle when I first set it up. Turns out I just needed a different combination of wires. Make sure all the throttle wires are in the right place, consider peeling off the shrink to check.

I was just succesful in making a no-spark circut on my blackcomb build. Here's a helpful link if you haven't figured everything out yet - http://www.scriptasylum.com/rc_speed/_nospark.html

^^make sure to click on the polarized/unpolarized option at the bottom and it'll show you how to wire it

The link doesn't show a diode being used; I am going to ask the guy who made the page if one is really necessary. The page says to leave it plugged in.. :?

Good luck on your build!

 

[itchynackers2]

Even if I peel back the shrink, I don't think it will help me. I don't really know how hall sensors are wired, so I won't know which wire to plug in a particular spot on the controller. I assumed they were in the correct "order" on both the throttle and controller. I'm really just stumped until/if I hear back from Kelly.

 

[itchynackers2]

Problems solved. Switched hall wires to controller.