INSTALLATION INSTRUCTIONS EZ-GO Installation Notes

INSTALLATION INSTRUCTIONS EZ-GO Installation Notes
1551 S. Vineyard Avenue
Ontario, CA 91761
(909) 923-1973
INSTALLATION INSTRUCTIONS
E-Z-GO Installation Notes
CURTIS 1234, 1236 OR 1238
AC INDUCTION MOTOR/ CONTROLLER
EZ-GO Curtis Controller Installation
1.
Disconnect Negative Battery Cable, Disconnect Positive Battery Cable.
2.
Disconnect all Motor and Controller wires.
3.
Remove original Motor, Controller & Reversing Switch (remove controllermounting plate, if equipped).
4.
Remove original wiring harness. Unplug any connector’s possible (cut as
little as possible). If equipped with rear brake lights, label and keep factory
wires from the brake pedal switch. These wires will be reused to enable the
brake lights. (See DIAGRAM 2.1)
5.
Install the Controller mounting plate in cart. See PICTURE 1.5. Installation of
the cables and wiring harness will be outlined in later steps.
6.
Bolt the Controller, ITS Converter & Solenoid to new mounting plate. Use
supplied ¼-20 bolts and lock washers.
7.
Install new AC 9 Motor. Use the supplied ¼-20 bolts and lock washers. Do not
over torque Motor Bolts.
8.
If clearance from the passenger shock mount to the motor’s fan shield is less
than one inch (viewing from the top), cut/trim passenger side rear. This
procedure is not needed if cart has been lifted. Not required if the cart is
lifted.
9.
If equipped, install the on-board Battery Charger. For Delta-Q Battery
Charger see Picture 1.6 and DIAGRAM 2.4 for reference.
10. Connect Motor Cables from the controller to the AC9 Motor at each
appropriate phase. Motor Cables and Battery Cables should be at least #2
AWG. See Picture 1.7 and DIAGRAM 2.8 for reference.
11. Connect one side of the solenoid to the Fuse Post on the Controller.
12. Connect Negative Battery Cable to the controller. (DO NOT connect to
Battery at this point).
Page 2 of 20
13. Install Wiring Harness. Refer to DIAGRAM 2.7
14. Use supplied cable adapter for throttle wires. Plug the flat connector into the
ITS converter box. Plug 4-pin square connector into mating connector on
wiring harness. Connect the Blue wire to the Blue wire on the solenoid, Red
to the Red, Green to the Green, White to the White & Black to the Black on
the ITS cable.
15. Connect wires to FWD/REV switch, See DIAGRAM 2.5 & 2.6. Connect the Blue
wire to the center connector tab. Connect the Yellow towards “F”, forward
and White towards “R”, reverse.
16. Drill a 2 1/16” hole in the dash panel for the BDI.
17. Plug cable with 8-pin connector into the back of the Dash Display.
18. Connect Red Wire to one side of Key switch.
19. Connect Blue wire to key switch.
20. Connect a Yellow wire from F & R switch to the positive side of the reverse
buzzer, and the Gray wire to the negative. See DIAGRAM 2.6.
21. Connect a Blue wire from the key switch to terminal 2 on the Golf/Street
switch, and the Brown wire to terminal 1. (Golf Mode is selected when
terminals 1 and 2 are connected together). See DIAGRAM 2.6 & 2.7 .
2 2 . For carts equipped with Rear Brake Light Kit, install a 12VDC automotive type
relay in a suitable location where both factory and system wires can be
connected together. The factory brake wires were disconnected and labeled
at step #4. The below connections can be reviewed by using the DIAGRAMS
2.2, 2.3 & 2.7
22.1. Connect the factory +12V source Red wire to the relay at terminal #30.
22.2. Connect the factory Brown wire of the rear brake lights to the Brake
Relay at terminal #87. Wire color may be different depending on
model year.
22.3. Connect a Blue wire from the key switch to the Brake Relay at terminal
#86.
22.4. Connect the Orange wire to the Brake Relay at terminal #85.
Page 3 of 20
22.5. Connect Blue wire to the COM on the Brake Switch, Connect the
purple wire to the N.C. terminal.
23. Connect White/Red wire to Menu Button. Connect other side of button to
Blue wire on the key switch. See DIAGRAM 2.6.
24. Connect Orange/White wire to the – (negative side of the Main Contactor),
and Blue/White wire to the + (positive side). Remove any diode, resistors.
25. Connect Fuse Wire and the + Battery cable to the Main Contactor. If On
Board charger is used, connect fuse wire to the Green wire from the charger.
26. Plug in Encoder Cable to the motor.
27. DOUBLE CHECK ALL CONNECTIONS.
28. Secure all wires, harnesses and cables to the cart’s frame by using tie straps.
29. Install 10 Amp fuse at the fuse holder in the system harness.
30. Connect – (negative) Battery Cable.
31. Test Cart on Jack Stands. There will be no motor damage if the motor initially
over speed. If motor runs slow and in the wrong direction, reverse the U and
W leads on the Motor.
Page 4 of 20
Driving the car with the A-C Drive System
When key switch is first turned on, the system needs about 2 seconds to come
online. After this time has expired, select the desired drive direction at the
Forward/Reverse switch and press the accelerator pedal. The drive wheels could be
in either direction when first turned on.
BDI: (Dash Gauge), the BDI will display Battery Charge level (LED’s at bottom) as
well as text messages.
BDI Message
Mode
MPH
Cart in Street Mode (displays vehicle speed)
GOLF
Cart in Golf Mode (see note below)
REVERSE
Cart in Reverse direction (see note below)
LOWBATT
Cart in Limp Home mode (see note below)
Menu System:
Battery Percentage:
State of Charge left in batteries.
TOC:
Time on Charge, Time in minutes since the last time the
car was charged.
Volts:
Battery Voltage
RPM:
Motor RPM
The last menu option is the vehicle odometer.
Street Mode gives the cart a Max speed of 25 Miles per hour. Acceleration &
Regenerative Brake torque are set at maximum level.
When in Golf Mode the cart speed is limited to 12 Miles per hour. Acceleration &
Regenerative Brake torque is also reduced.
Page 5 of 20
Drive Mode can be changed on “The Fly”. There is no need to stop the cart when
changing from Street to Golf or vice-versa.
When Cart is in Reverse, speed is reduced to 8 Miles per hour. Acceleration &
Regenerative Braking torque is also reduced.
Limp Home mode is automatically activated when the Battery charge level has
dropped below 20%. The maximum cart speed is restricted up to 15 Miles per
hour at Street mode. It is recommended to charge the batteries as soon as
possible to prevent damage to the batteries from being over discharged.
Page 6 of 20
Instructions for Throttle Set Up
For systems set up after March 2007 with Version 8.00U software
With Key OFF, Select Forward Direction, Release Parking Brake, Press and hold the
“Menu” Button, then turn the Key “ON”. Hold Menu Button until “Program”
appears on the Dash Display, then release.
If the cart has a brake pedal switch:
Use the Brake Pedal to cycle through the options. Have the Golf/Street Mode
switch set to “Street Mode”, (MPH), to change parameters.
If the cart does not have a brake pedal switch:
Select “Golf Mode” and press the “Menu Button” to cycle through the options.
To change a parameter in any of the options:
Select “Street Mode” and press the “Menu Button” to change a parameter or
activate an option.
T Type: This is the Throttle Pot Type Parameter. For 0-to-5k, 2-wire throttle pots,
set to type 3. For 3-wire throttle pots or EZ Go with ITS converter box, set to Type
2. The default is Type 2.
Throttle: This allows the Throttle range to be calibrated.
Cycle the program options to “Throttle” on the Dash Display, select Street Mode,
press the Accelerator Pedal to the floor (Max Throttle).
With the pedal pressed, press and hold the “Menu” Button and the display will
show “HoldMenu”. Maintain the pedal and menu button pressed until the
display reads “Turn OFF”. After this message is displayed, turn off the Key. DO
NOT release the accelerator pedal or the Menu button before turning OFF the
Key. The Throttle is now calibrated.
Using this procedure will ensure full throttle range; if this procedure is not
performed the calibration will be at to a default setting. Use this set up procedure
for 2-wire, 0-to-5k, three wire throttle or EZ Go with ITS converter box types.
Page 7 of 20
Rst: This is the BDI reset voltage per battery cell. Adjust only if there is a problem
with the BDI resetting to 100% when the batteries are below 85% and have not
been charged or not resetting after a charge.
To increase the parameter, select “Forward” and “Street Mode”, then press the
Menu button.
To decrease, select “Reverse” and “Street Mode”, then press the Menu button.
The default is 2.125 volts per cell; this should work fine in most applications.
Mode: Sets the Motor Control Mode. The control mode can be set as Mode 1 or
Mode 2
Mode 1 is Speed Control. Speed Control means the accelerator pedal controls the
actual speed of the vehicle.
For example: In Speed Control Mode if you set the accelerator pedal to half, you
will go half speed, uphill, downhill or on flat ground. Speed Mode is great if you
are looking for controlled descents down hills and want to use the brakes a little
as possible. It does however have more of a jerky feel when changing speeds with
the accelerator pedal.
Mode 2 is Torque Control Mode. Torque control is the same type of control
method a DC motor has. The accelerator pedal controls the amount of torque the
motor produces. This gives a much smoother feel when changing the accelerator
position. Brakes will be used more in downhill descents.
Brk%: Only available if the Speed Mode is set to “2”. This sets the amount of
Regen when the Brake Pedal is pressed.
To increase the parameter, select “Forward” and “Street Mode”, then press the
Menu button. To decrease, select “Reverse” and “Street Mode”, then press the
Menu button.
If the default braking level is desired, leave this set to Zero. The Default is 40%. So,
setting to 1% would be the lowest setting and give almost no Regen.
Page 8 of 20
Instructions for using On Board Diagnostics
With the Key OFF, Select Reverse Direction, Press and hold the “Menu” Button.
Turn Key the “ON”, hold Menu Button until “Diagnose” appears on the Dash
Display, then release the Menu Button. Pressing and releasing the menu button
will scroll through the Diagnostic options. The cart can be driven during diagnostic
checks.
T Sw: This monitors the state of the Throttle Switch. With the pedal in the idle
position the display should read “OFF”, when the pedal is pressed the display
should change to “ON”. If “OFF” is always displayed there is a problem with the
switch on the throttle pedal. This test can be performed in “Neutral” or with
either direction selected.
TPV: This is the raw Throttle pot voltage. This test should be performed with the
car in “Neutral”. 0.2 volts is normal for idle position, at full throttle, 3.5 volts for 2
wire pots, and 5.0 volts for 3 wire pots.
T Max: This is what the Max Throttle Voltage Parameter is set at. For example: If
the Parameter is set at 4.5, then the TPV will need to reach 4.5 for full speed to be
obtained. Use the Throttle calibration procedure if adjustments are necessary.
Req %: This is the amount of throttle being requested of the controller. This
should be a number from 0 to 100% when the car is being driven.
Brk: On or Off. Checks to ensure brake switch signal input to the controller.
Should be ON when the brake pedal is pressed and OFF when the brake pedal is
released.
Page 9 of 20
CapV: This is the voltage on the Capacitor Bank inside the controller. This voltage
should be at or near the voltage of the Batteries. When the Throttle is pressed,
this sends a signal to the controller to pre-charge the Capacitor Bank and turn the
Main Solenoid ON. If this voltage is low or at 0, this means there is probably a
failure in the Pre-Charge circuit and the controller will need to be repaired or
replaced.
EncA & EncB: These are the Motor Encoder signals shown in RPM. This can be
used to troubleshoot either an Encoder failure, or a problem in the Encoder
wiring. If the motor turns slow and in the proper direction, check the RPM of both
signals. If EncA has no signal, the Display will read Zero. The same applies to EncB.
EncA involves with White, (sometimes Brown), wire on the encoder connector,
EncB is the Green wire. On an EZGO, these colors are reversed.
Main: This is the state of the Main Contactor, see table below:
0 = Open, Solenoid not turned on.
1 = Pre-charge.
2 = Weld check, the controller is checking for welded contacts.
3 = Closing Delay
5 = Closed, the Solenoid coil is energized and the contacts should be closed.
6 = Open Delay, after the cart is stopped there is a delay of about 5 seconds for
the Solenoid to open.
OS: This is the Version of the Operating System in the controller.
Build: This is the Build number of the Operating System.
Ver: This is the VCL (vehicle control language) version number.
D/C: This is the date when the controller was manufactured. 6123=the 123rd day
of 2006
Page 10 of 20
S/N: This is the unique serial number of the controller.
Faults: If any, will be displayed.
Fault Codes
Fault codes will display on the Dash Display when they happen, the “Wrench” on
the display will also light up.
Code 12, Controller Over Current
Code 13, Current sensor fault
Code 14, Precharge Failure
Code 16, Controller Over Temperature
Code 17, Severe Undervoltage
Code 18, Severe Overvoltage
Code 25, 5-volt power supply failure
Code 36, Encoder Fault, see diagnose, EncA & EncB.
Code 37, Motor Open or Open Phase on controller fault
Code 38, Main Solenoid welded
Code 39, Main Solenoid not closing
Code 73, Stall detected, No encoder signal, see diagnose, EncA & EncB.
Page 11 of 20
Picture 1.5
Picture 1.6
Picture 1.7
Page 12 of 20
EZ-GO FACTORY BRAKE LIGHT KIT WIRING DETAIL
-DIAGRAM 2.1
BRAKE PEDAL
BRAKE SWITCH
RED
FROM +12V
BATTERY
BROWN
TO FACTORY
BRAKE LIGHT
Page 13 of 20
HPEV AC-9 SYSTEM BRAKE LIGHT WIRING DETAIL
-DIAGRAM 2.2
NORMALLY
CLOSED
BRAKE PEDAL
COMMON
BLUE
NORMALLY
OPEN
PURPLE
BRAKE SWITCH
WIRING DETAIL
PURPLE
(Normally
Closed)
BRAKE
SWITCH
BLUE
(COMMON)
HPEV SYSTEM
WIRING
HARNESS
RED
FROM +12V
BATTERY
DISCONNECT FACTORY BRAKE
LIGHT WIRES AND RECONNECT TO
A 12V AUTOMOTIVE RELAY
(SEE DIAGRAM 2.3)
BROWN
TO FACTORY
BRAKE LIGHT
Page 14 of 20
BRAKE LIGHT REWIRING RELAY DETAIL
-DIAGRAM 2.3
BROWN
TO FACTORY
BRAKE LIGHTS
ORANGE
FROM HPEV
SYSTEM
HARNESS
FROM HPEV
SYSTEM
HARNESS
87
BLUE
86
85
30
RED
BRAKE LIGHT
RELAY
FROM +12V
BATTERY
Page 15 of 20
EZ-GO WIRING HARNESS with ON BOARD DELTA -Q BATTERY CHARGER DIAGRAM 2.4
FORWARD/ REVERSE
SWITCH
WHITE
RED-YELLOW
SEE DIAGRAM 2.5
RED-YELLOW
BLUE
YELLOW
PURPLE
BLUE
6 PIN PLUG TO
MOTOR ENCODER
PARK SWITCH
BRAKE SWITCH
BLUE
GREEN
BLACK/ WHITE
PURPLE/ WHITE
35 PIN CONNECTOR
THROTTLE
CONNECTIONS
YELLOW/ WHITE
WIRE BUNDLE
YELLOW
GRAY
BLUE
BROWN
ORANGE
DASH
PANNEL
SEE
DIAGRAM 2.6
RED
WHITE/ RED
FUSE 10A
RED
8 PIN DISPLAY PLUG
GREEN
TO BATTERY
POS (+)
#2 CABLE
BLUE/ WHITE
+
Main
Contactor
TO CONTROLLER POS (+)
MAIN FUSE #2 CABLE
WHITE
BLACK - HOT
BLACK
-
RED
ORANGE/ WHITE
WHITE - NEUTRAL
GREEN - GROUND
110 VOLT AC
PLUG
TO BATTERY NEG. (-)
TO BATTERY POS. (+)
Page 16 of 20
FORWARD/ REVERSE SWITCH DETAIL
- DIAGRAM 2.5
YELLOW
FWD
BLUE
REV
WHITE
Page 17 of 20
EZ-GO DASH PANEL WIRING DETAIL - DIAGRAM 2.6
YELLOW
REVERSE
BUZZER
GRAY
YELLOW
FWD
BLUE
REV
WHITE
FORWARD/
REVERSE
SWITCH
BROWN
WHITE / RED
MENU
BUTTON
1
BLUE
BLUE
2
BLUE
GOLF/
STREET
SWITCH
RED
KEY
SWITCH
DASH
DISPLAY
BDI CABLE
Page 18 of 20
REVISIONS
NOTICE:
This drawing is the property of Hi Performance Electric Vehicle Systems Inc., and/or its subsidiaries and affiliates
(individually and collectively “HPEVS”), and contains highly proprietary, confidential, and trade secret information of HPEVS. The
recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by HPEVS
(b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing.
REV ORIGINATOR
C
FORWARD / REVERSE
SWITCH (NOTE *1)
87
30
85
86
12V IN
TO BRAKE LIGHTS
BRAKE
LIGHTS
RELAY
WHITE 18 AWG
FOWARD
YELLOW 18 AWG
REVERSE
4
5
6
7
8
9
10
11
12
14
16
17
18
19
20
24
25
29
30
31
32
33
34
35
MAIN CONTACTOR COIL
ORANGE/ WHITE18 AWG
MENU BUTTON
(NOTE *2)
I/O GROUND
BLACK/ BLUE 18 AWG
MOTOR TEMP SENSOR
YELLOW/ BLACK 18 AWG
PEDAL INTERLOCK
GREEN 18 AWG
MENU BUTTON
WHITE/ RED 18 AWG
BRAKE SWITCH
PURPLE 18 AWG
GOLF / STREET SWITCH
BROWN 18 AWG
COIL RETURN
BLUE/ WHITE 18 AWG
YELLOW 18 AWG
BLUE 18AWG
BACK UP BUZZER
GOLF / STREET
SWITCH
ORANGE/ WHITE18 AWG
N/C
BLACK/ WHITE 18 AWG
POT WIPER
YELLOW/ WHITE 18 AWG
P2
N/C
N/C
N/C
PEDAL INTERLOCK
GREEN 18 AWG
POT WIPER
YELLOW/ WHITE 18 AWG
POT HIGH
BLACK/ WHITE 18 AWG
I/O GROUND
BLACK/ BLUE 18 AWG
N/C
WHITE 18 AWG
N/C
R2
MOLEX
MINI FIT JR
39-01-2041
N/C
FOWARD
MAIN
CONTACTOR
(NOTE *3)
BLUE/ WHITE 18 AWG
POT HIGH
BLUE 18 AWG
MOLEX
MINI FIT JR
39-01-2040
1
1
2
2
GREEN 18 AWG
RED 18 AWG
3
3
BLUE 18 AWG
4
4
WHITE 18 AWG
2
3
N/C
BLACK 18 AWG
RED/ BLUE 18 AWG
5V POWER CNTRL
RED/WHITE 18 AWG
N/C
TX SERIAL
GREY/ BLUE 18AWG
RX SERIAL
GREEN/ WHITE 18 AWG
ENCODER PHASE A
TAN 18 AWG
TAN/BLACK 18 AWG
REVERSE
YELLOW 18 AWG
I/O GROUND
BLACK/ BLUE 18 AWG
TX SERIAL
GREY/ BLUE 18AWG
12V POWER CNTRL
RED/ BLUE 18 AWG
RX SERIAL
GREEN/ WHITE 18 AWG
ITS
1
BLACK 18 AWG
DISPLAY
5
MOLEX MINI FIT JR
39-01-2080
Note: Pins 2, 3, 4, &
7 are not connected
1
R5
TAN 18 AWG
MOTOR ENCODER
CABLE
1
1
2
2
3
3
TAN/ BLACK 18 AWG
(*2) MENU BUTTON IS OPTIONAL USE WITH DISPLAY.
4
4
(*3) REMOVE ANY DIODES OR RESISTOR FROM MAIN CONTACTOR.
BLACK/ BLUE 18 AWG
(*4) USE 400A FUSE IN 650 SYSTEM. USE 300A FUSE IN 350 SYSTEM.
YELLOW/ BLACK 18 AWG
5
5
6
6
MOLEX SL SERIES
50-57-9405
W
V
U
RED/ WHITE 22 AWG
1
BLACK/ BLUE 22 AWG
N/C
2
TAN 22AWG
3
(*1) IF REVERSE IS NOT USED, CONNECT WHITE WIRE TO BLUE WIRE.
TAN/ BLACK 22 AWG
4
BLACK 22 AWG
MOTOR
5
CAD TYPE
VISIO
OPER. NO.
CAD LOC.
CAD FILE
UNIT
DRAWING
DESIGN
DETAIL
TITTLE
CHECKED
SAFETY
PURPLE 22 AWG
(*5) NORMALLY OPEN. CONTACTS MUST BE CLOSED WHEN BRAKE PEDAL
IS PRESSED.
R4
(*6) MOTOR TEMP SENSOR NOT USED FOR GOLF CART APPLICATION.
2
400A
(NOTE *4)
R3
6
DEUTSCH
DTM-04-6P
RED/ WHITE 18 AWG
BLACK/ BLUE 18 AWG
NOTES:
4
3
8
P4
N/C
N/C
4
5
WHITE 18 AWG
N/C
ENCODER PHASE B
ITS
THROTTLE
UNIT
6
1
S1
12V POWER CNTRL
-
+
U
28
GRAY 18 AWG
N/C
V
27
BACK UP BUZZER
10A
BLUE 18AWG
W
26
BLUE 18AWG
35 PIN CONNECTOR
(SEE R1)
23
ORANGE 18 AWG
N/C
B+
22
BRAKE RELAY
RED 18AWG
S2
B-
21
BLUE 18AWG
-A2
15
+48V OR 72V
+A1
13
BLUE 18 AWG
ITS
CONVERTER
3
BLUE 18AWG
MOTOR ENCODER
2
11/17/2011
BRAKE SWITCH
(NOTE *5)
R1
KSI
APPROVED
KEY SWITCH
KSI
AMP
776164-1
1
DESCRIPTION
M AJOR REVISION; M ISSING
DIM ENSIONING WERE ADDED
MOTOR TEMP
SENSOR
(NOTE *6)
DEUTSCH
DTM-06-6S
SCALE
NONE
DATE
12/21/10
DRW SIZE B
1010-EZ-GO
EZ-GO GOLF CART
SYSTEM SCHEMATICS
REVISION C
SHEET 1
OF
1
HPEVS SYSTEM WIRING DETAIL - DIAGRAM 2.7
Page 19 of 20
HPEVS
HIGH CURRENT WIRING DETAIL - DIAGRAM 2.8
FRONT OF
CART
CONTROLLER
V
U
Main
Contactor
+
B+
W
B35 PIN
CONNECTOR
FUSE
-
ORANGE/ WHITE
BLUE/ WHITE
U
V
W
MOTOR
6 PIN
TO WIRING
HARNESS
Page 20 of 20
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