ATG (Jul/Aug14) – Bench Testing

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Q: S.K. Writes: Mr. Kramer can you please help with some sort of bench testing for controllers so we can run them before we install them?

According to Roger: For some reason this suddenly has been a hot topic. It seems you are not the only one with that request. A test stand not only speeds up processes it helps you with troubleshooting. You will find by taking the time to build one it also becomes a training aid for your techs. It can be used as a Demo Unit for your show room to explain the features and benefits of the motor system you are selling. Ultimately, that is our goal, profit from sales. The more you can educate your clients and personnel, the profit levels will increase. This may become a two or three part answer as this is a very large subject and will not fit into the allotted space I have. That is why sometimes I write condensed versions of things. This one we cannot do that.

So to start with let’s talk about materials. This will depend on how elaborate you want to be.

Switches:
3 Single pole single throw rated at 3 amps will suffice (Mini)
1 Double pole double throw rated at 3 amps will suffice (Mini)
1 Plastic project box 6” X 3” X 2” (you can use smaller just make sure it will accommodate all of the parts)
1 Linear potentiometer rated a 5K to 0 (1/4” shaft)
1 Knob for potentiometer (1/4” ID)
1 Contactor (solenoid) rated at 36 volts
1 Contactor (solenoid) rated at 48 volts
1 Shunt wound motor (closed)
1 Series wound motor (closed)
1 Non conductive mounting board 36” X 18” X 3/4”
1 Push cart or metal frame to mount the parts to (Harbor Frieght)
Spools of 18 gauge wire of assorted colors
Assorted wire ends
Assorted cable ends (6 gauge)
Roll of cable (6 gauge) 15 to 20 foot depending on system (series or shunt)
10/12 Gauge wire (red and black) and cut to length (shunt system)
2 Molex nine pin connector (optional)
2 Single pole double throw contactors (solenoids) for series systems or use a manual forward/reverse shifter. Contactors will give a cleaner look. 36 and 48 volt.
1 Diode rated at 3 amps
1 Pre-charge resistor rated at 250 ohms
1 Ferro-resonant 20 or 30 amp charger (two connected in parallel will double output for amperage)

The mini switch can be found at Radio Shack along with the potentiometer and knob. The contactors should be in your golf car stock. The motor can be ordered through your sales representative. Cables and wire you should have in your warehouse. You can use a PB-6 Pot-Box but that limits you to a 5K to 0 wipe. We will discuss resistive wipe, ITS and voltage for throttle inputs as we go along. In your stock pile of old battery chargers you should have a charger. Or you can use batteries if you have extra and the room to fit them.