Go Back   DIY Go Kart Forum > Building Plans And Advice > Electric Projects

Notices

Reply
 
Thread Tools Display Modes
  #21  
Old 05-30-2019, 07:15 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Hmm I tried to upload a video but at the end of uploading it it said error uploading, it canít be too big as as itís only 30 seconds and done on an Iphone, Iíll keep trying, Iíll probably get a few pics on here once itís back together,
Thanks again for the info functional artist, whatís your name anyway, I canít keep saying functional artist
Reply With Quote
  #22  
Old 05-30-2019, 07:43 AM
landuse's Avatar
landuse landuse is offline
Moderator
 
Join Date: Nov 2010
Location: Pietermaritzburg, South Africa
Posts: 17,409
Thanks: 2,158
Thanked 3,485 Times in 2,843 Posts
Default

Quote:
Originally Posted by Bigfillly View Post
Hmm I tried to upload a video but at the end of uploading it it said error uploading, it canít be too big as as itís only 30 seconds and done on an Iphone, Iíll keep trying, Iíll probably get a few pics on here once itís back together,
Thanks again for the info functional artist, whatís your name anyway, I canít keep saying functional artist
His name is Kevin
Reply With Quote
The Following 2 Users Say Thank You to landuse For This Useful Post:
Bigfillly (05-31-2019), Functional Artist (05-30-2019)
  #23  
Old 05-30-2019, 12:40 PM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Thanks
Reply With Quote
  #24  
Old 06-01-2019, 12:39 PM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Well it’s bad news I afraid, I swapped out the rectifier but the controller is still stuck with just the red light on, I’ll remove all the white stuff on the circuit and inspect the other components :-(
Reply With Quote
  #25  
Old 06-02-2019, 07:55 AM
Functional Artist's Avatar
Functional Artist Functional Artist is offline
Senior Member
 
Join Date: Jul 2016
Location: Toledo, Ohio
Posts: 2,007
Thanks: 778
Thanked 759 Times in 602 Posts
Default

Quote:
Originally Posted by Bigfillly View Post
Hi all,
Iím building an electric go kart and got all the components, they are:-
Montenergy 2000w-4000w 48v 98a motor
Kelly kdz48300 300a controller
Contactor
Foot pedal accelerator
The only thing Iím missing is the resistor that goes across the contactor,
Can anyone give me a clue how to work out which I need,
Thanks very much,
Phil.
Hey Phil,
Yup, my name is Kevin.

Well that SUCKS!

Hmmmmmmmmmmmmm
...missing the (precharge) resistor that goes across the contactor?

From what I understand, this resistor precharges the capacitators in the controller. This let's them fill up slowly so they don't get SLAMMED with the full pack voltage when the system is first turned on.

If the previous owner (set up for a boat) used that controller without a precharge resistor, that could be (at least part of) the problem.

Can you tell where the "white stuff" came from?
...or what it is?
__________________
RESISTANCE IS FUTILE
Reply With Quote
  #26  
Old 06-03-2019, 10:41 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Hi Kev,
I have the precharge resistor in place, I think it was a metal key start I used, i tested it and it sends 5v though the metal case when switched on, this goes through the metal it’s mounted on, then through the frame, then to the controller case which is mounted to the frame,
The white stuff is in all Kelly controllers, it’s something they put over the components so you can’t work on them yourself,
I’ll remove it one day,
Thanks,
Phil.
Reply With Quote
  #27  
Old 06-03-2019, 01:58 PM
Bmr4Karts Bmr4Karts is offline
Senior Member
 
Join Date: Apr 2019
Posts: 119
Thanks: 140
Thanked 37 Times in 28 Posts
Default

I'm getting closer to starting the actual building stage of my kart. I have a question related to this thread. What is the purpose of the contactor? Is it just a high amp relay that is controlled by low current switch?
Reply With Quote
  #28  
Old 06-03-2019, 05:30 PM
Functional Artist's Avatar
Functional Artist Functional Artist is offline
Senior Member
 
Join Date: Jul 2016
Location: Toledo, Ohio
Posts: 2,007
Thanks: 778
Thanked 759 Times in 602 Posts
Default

Quote:
Originally Posted by Bmr4Karts View Post
I'm getting closer to starting the actual building stage of my kart. I have a question related to this thread. What is the purpose of the contactor? Is it just a high amp relay that is controlled by low current switch?
Yup
__________________
RESISTANCE IS FUTILE
Reply With Quote
The Following User Says Thank You to Functional Artist For This Useful Post:
Bmr4Karts (06-03-2019)
  #29  
Old 07-19-2019, 07:58 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Hello again,
Sorry for the long update but I now have in my hands a brand new Kelly controller, I also got them to send me the correct resistor and diode for the contactor (just incase) I have 2 of each though, am I supposed to connect them both together?
Click image for larger version

Name:	B90CCBC5-982B-4015-AEE1-15C102068BAC.jpg
Views:	3
Size:	380.5 KB
ID:	110039
Thanks,
Phil.
Reply With Quote
  #30  
Old 07-19-2019, 10:02 AM
Functional Artist's Avatar
Functional Artist Functional Artist is offline
Senior Member
 
Join Date: Jul 2016
Location: Toledo, Ohio
Posts: 2,007
Thanks: 778
Thanked 759 Times in 602 Posts
Default

Kelly Controls set me (2) diodes too
...but, just (1) (10W 1KJ) resistor
(not sure why they sent (2) to you)

The resistor can be positioned either way
...but, the diodes must be positioned a certain way
(with the stripe toward the "power out" side of the contactor)
(see last pic below)

The leads on the diode were long enough to just crimp on some ring terminals
...but, I had to add some extension wires to the resistor, so it would reach from terminal to terminal

Here is a video with some info (on the subject)

Attached Thumbnails
SAM_5858.jpg   SAM_5898.jpg  

SAM_5899.jpg   SAM_5909.jpg  

SAM_5921.jpg  
__________________
RESISTANCE IS FUTILE
Reply With Quote
The Following User Says Thank You to Functional Artist For This Useful Post:
Bigfillly (07-19-2019)
  #31  
Old 07-19-2019, 11:17 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Hi Kev,
Thanks very much for stepping in again
I guess I’m use the bigger resistor out of the 2 and 1 diode,
on your drawing you have a green wire and a red wire, the diode has the band at the red wire, is that your positive wire, or doesn’t it matter as long as it the stripe is on the power out of the solenoid?
Thanks again,
Phil.

---------- Post added at 05:17 PM ---------- Previous post was at 04:27 PM ----------

Hi again,
I’m probably being daft but is there pin outs that turn the contactor on, I was using a separate switch for this previously,
Thanks again,
Phil.
Reply With Quote
  #32  
Old 07-19-2019, 11:40 AM
Functional Artist's Avatar
Functional Artist Functional Artist is offline
Senior Member
 
Join Date: Jul 2016
Location: Toledo, Ohio
Posts: 2,007
Thanks: 778
Thanked 759 Times in 602 Posts
Default

Referring back to the diagram (on page 12)
https://kellycontroller.com/wp-conte...UserManual.pdf

The red wire provides the positive (+) power (notice it's full pack voltage) from the battery pack
(via the key switch)
...to the contactor
…& also to the speed controller J2-1 (PWR)

The green wire provides the negative (-) to complete the circuit
…& goes directly from the contactor "coil" to the J1-3 (Main Rly)

When the key switch is activated, the contactor & the speed controller get "powered" @ the same time (by the red wire)
…& the green wire is how the speed controller turns the contactor off thus "killing" the power going to the motor (like in a low voltage situation or emergency shut down)

* Notice (in the pic below) I have "highlighted" the (J2-1) positive (+) wire red
...but, I didn't "highlight" the (J1-3) negative (-) in green

* The diagram notes a 10W 1 KOhm resistor

It also indicates the diodes values @ (200V/3A)
…& the proper "stripe" direction
Attached Images
 
__________________
RESISTANCE IS FUTILE
Reply With Quote
The Following User Says Thank You to Functional Artist For This Useful Post:
Bigfillly (07-20-2019)
  #33  
Old 07-19-2019, 01:25 PM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Awsome answer and pics once again, I thank you greatly for all the replies you’ve done so far, I’ll hopefully get it all working again tomorrow,
I’ll get a video up for you soon,
Thanks again kev
Phil
Reply With Quote
  #34  
Old 07-20-2019, 05:02 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

i got it all together this morning and it seems ok, it still moves without any throttle though?
Hereís the link to the video,
https://youtu.be/hCi7Omi4ADc
Iíll try it out sometime today when the weather picks up
Thanks again Kev for all the time youíve spent replying, without you expertise, I would have struggled
Reply With Quote
  #35  
Old 07-20-2019, 06:40 AM
Functional Artist's Avatar
Functional Artist Functional Artist is offline
Senior Member
 
Join Date: Jul 2016
Location: Toledo, Ohio
Posts: 2,007
Thanks: 778
Thanked 759 Times in 602 Posts
Default

It still seems to be getting a signal from the throttle

Could be a defective throttle, improperly adjusted or binding

Test:
Disconnect the throttle (to remove it from the equation)
…& turn the system on to see if the motor still moves/turns

If it doesn't turn anymore, it indicates there is a throttle problem
...if it does, you have other problems

You could also test the throttle

When the throttle is connected, there should be 0V (zero voltage) coming out of the "signal" wire
…& when activated/twisted it should slowly rise from zero up to ~4.5V-5V

*Your very welcome, glad I can help
__________________
RESISTANCE IS FUTILE
Reply With Quote
  #36  
Old 07-20-2019, 11:43 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

I have one of the wires from the throttle on a switch at the moment, so when the controller is turned on it doesn’t throws an error out,
The throttle is brand new but it did it from day one, if it’s not connected it’s fine, I’m not too bothered at the moment about it,
LETS TALK SOFTWARE
I have the disc and I’ve tried to load it on a laptop, it says it’s installed but there isn’t a shortcut to click on for programming,
Is there a link that I can download the software from, I’ve been searching for 3 hours and got nowhere, all the links say “this page is no longer available”
Thanks,
Phil.
Reply With Quote
  #37  
Old 07-20-2019, 01:56 PM
Functional Artist's Avatar
Functional Artist Functional Artist is offline
Senior Member
 
Join Date: Jul 2016
Location: Toledo, Ohio
Posts: 2,007
Thanks: 778
Thanked 759 Times in 602 Posts
Default

I have not done any of the "software" stuff yet
...but, it's on my "to do list"

Maybe Sid can help with this question
...or email Fran @ Kelly Controls & ask her.
__________________
RESISTANCE IS FUTILE
Reply With Quote
  #38  
Old 07-21-2019, 06:52 AM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Iíll get in touch with them, I need to tinker about with the settings, thanks again
I got my lad on the kart and this is it
https://youtu.be/JdaWyZTlVts
Iíve just bought a smaller rear sprocket so it pulls off little quicker but for now itís pretty good,
Reply With Quote
  #39  
Old 07-22-2019, 01:06 AM
landuse's Avatar
landuse landuse is offline
Moderator
 
Join Date: Nov 2010
Location: Pietermaritzburg, South Africa
Posts: 17,409
Thanks: 2,158
Thanked 3,485 Times in 2,843 Posts
Default

Quote:
Originally Posted by Bigfillly View Post
Iíll get in touch with them, I need to tinker about with the settings, thanks again
I got my lad on the kart and this is it
https://youtu.be/JdaWyZTlVts
Iíve just bought a smaller rear sprocket so it pulls off little quicker but for now itís pretty good,
Dang!! That thing moves fast
Reply With Quote
  #40  
Old 07-22-2019, 12:35 PM
Bigfillly Bigfillly is offline
Junior Member
 
Join Date: Mar 2019
Location: In a shed in the U.K.
Posts: 23
Thanks: 7
Thanked 3 Times in 3 Posts
Default

Ha ha thanks very much,
Iíve just changed the settings to max, they were nearly set to max before so it may not go much faster, ill fit the smaller rear sprocket mid week and get it out again and see what itís like,
Thanks again,
Phil.
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off



All times are GMT -6. The time now is 04:36 AM.