VEC500 72V +10kW motor new setup, EV lock voltage

[Alexf]

Hi,

We're working on an amphibious vehicle using golden motor set up for land based travel. Great product for a fun project.

My question is what is the voltage used by the Ev lock wires on our VEC 500 72v controller? Any chance it's 12 or 24m

My understanding is that contractors normally use a lower voltage to initialise the relay but not sure if that applies.

I'm struggling to locate switches rated to 72v here in NZ so hopeful the 12 / 24 varieties will work.

Thanks!

Alex

[Bikemad]

Hi Alex andto the forum.

With the GM controllers it is the full battery voltage that is being switched as shown in this diagram:


However, I'm not sure if this diagram is 100% accurate, as the e-lock wire appears to be connected directly from the battery + connection on the contactor, but I don't know whether the e-lock wire should also be switched via the throttle mounted e-lock switch as I've shown it here:



If a contactor is not fitted, the e-lock switch simply switches the 72V battery voltage to the e-lock wire on the controller, but when a contactor is fitted the e-lock switch switches battery voltage to energise the contactor's 72V coil.

If your vehicle already has a 12V battery for ignition and/or starting/lighting purposes, you could then use a contactor with a 12V coil powered from the existing 12V battery (either through the existing ignition switch or via a separate switch).

Should you need to switch full battery voltage to a 72V contactor, most 12/24V switches will be capable of doing this, as they would only be switching a very low current of ~200mA (~0.2A) at 72V to keep the contactor coil energised.

You could also wire in a 72V to 13.8V DC/DC converter to the switched output side of the contactor (Battery supply to controller) to keep the 12V battery topped up while running on land and to power the lighting and horn etc.

Looking forward to hopefully seeing some pictures (and eventually some video) of this unusual vehicle. 

Alan
 

[Hans]

Dear Alan,

I just found your post regarding the connection between contactor and e-lock, which makes way more sense than the official drawing. Have you tested it that way and did it work? And I assume you've added an additional cable to connect to the smaler side of the contactor and the elock? As my wiring harness only has two cables on the e-lock side?

Thank you and kind regards from Germany,
Hans

[Bikemad]

Hi Hans andto the forum.

I haven't tested it because I only have ebikes fitted with Magic Pies and Smart Pies, and nothing that uses a VEC controller. 

I haven't added any additional wires, I have simply drawn it with the e-lock wire connected to the switched side of the e-lock switch, which is where I would have expected it to be connected.

I don't know whether the original "WITH CONTACTOR" diagram is correct or not, I simply pointed it out because it seems very unusual to have the e-lock wire permanently connected directly to the battery feed via the e-lock connector instead of being switch through the e-lock switch.

Either the drawing has been accidentally drawn incorrectly, or the drawing is correct and the e-lock wire needs to be connected as per their diagram for some undocumented reason. 

I also don't know if the VEC controllers have the ability to precharge the controller's capacitors, as would typically occur with most controllers before the contactor is energised.

Alan
 

[Hans]

Dear Alan,

thank you for your reply. I did stumble one the same point and couldn’t think of a logical explanation for the wiring being the way it is on the diagram. So I felt very releaved to find someone how thinks the same 😊 I guess I will have to try weather it is working or not when connecting it the given way.

Kind regards
Hans