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Discussion Starter #1
I have purchased a motor and a motor controller and am looking to move into the final stages of wiring and mounting my motor and components to finish the conversion for my ATV. I have bought the following components:

Mars ME0909 Motenergy Motor
Curtis 1205M 48V 500A Motor Controller

I have made this "Casual Schematic" Sketch and Parts Spreadsheet (Linked at bottom) and would love feedback. I am a complete newbie with EV Conversions and need as much help with wiring and mounting as I can get. Any guidance would be greatly appreciated!

Thank You

Sketch:
https://docs.google.com/drawings/d/129jUCdfV79cwngP6k5tdTFKDaVv9dwjIsLRZEsC13V0/edit?usp=sharing


Parts Spreadsheet: https://docs.google.com/spreadsheets/d/1_qoedr6aQgT1mJhUCJhI5fSgJsbiZtyf3rmoPsWetG4/edit?usp=sharing
 

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I have purchased a motor and a motor controller and am looking to move into the final stages of wiring and mounting my motor and components to finish the conversion for my ATV. I have bought the following components:

Mars ME0909 Motenergy Motor
Curtis 1205M 48V 500A Motor Controller

I have made this "Casual Schematic" Sketch and Parts Spreadsheet (Linked at bottom) and would love feedback. I am a complete newbie with EV Conversions and need as much help with wiring and mounting as I can get. Any guidance would be greatly appreciated!

Thank You

Sketch:
https://docs.google.com/drawings/d/129jUCdfV79cwngP6k5tdTFKDaVv9dwjIsLRZEsC13V0/edit?usp=sharing


Parts Spreadsheet: https://docs.google.com/spreadsheets/d/1_qoedr6aQgT1mJhUCJhI5fSgJsbiZtyf3rmoPsWetG4/edit?usp=sharing
Hi dsu,

Nice start on wiring diagram, but needs more. Pre-charge resistor and ksi, for example. See https://www.google.com/search?source=hp&ei=byugWZzhDoqHjwSDtoWoDg&q=curtis+1205+wiring&oq=curtis+1205&gs_l=mobile-gws-hp.1.4.0l3j0i22i30k1l2.2806.10059.0.13635.12.12.0.7.7.0.463.2752.0j7j3j0j2.12.0....0...1.1j4.64.mobile-gws-hp..0.12.1185.3..41j0i131k1.oZcc-p2pAIc#imgrc=vEdeVaWDzrqIKM:

Also, your gear ratio seems low. Like about 3 : 1. Think needs to be more like about 5 : 1. Too low (numerical) ratio results on low wheel torque meaning slow accelerations with excessive current often burning motor brushes. Do your calculations for ratio and post here.

Regards,

major
 

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Discussion Starter #3
Hi dsu,

Nice start on wiring diagram, but needs more. Pre-charge resistor and ksi, for example. See https://www.google.com/search?source=hp&ei=byugWZzhDoqHjwSDtoWoDg&q=curtis+1205+wiring&oq=curtis+1205&gs_l=mobile-gws-hp.1.4.0l3j0i22i30k1l2.2806.10059.0.13635.12.12.0.7.7.0.463.2752.0j7j3j0j2.12.0....0...1.1j4.64.mobile-gws-hp..0.12.1185.3..41j0i131k1.oZcc-p2pAIc#imgrc=vEdeVaWDzrqIKM:

Also, your gear ratio seems low. Like about 3 : 1. Think needs to be more like about 5 : 1. Too low (numerical) ratio results on low wheel torque meaning slow accelerations with excessive current often burning motor brushes. Do your calculations for ratio and post here.

Regards,

major
1. I was told that a pre-recharge resistor was unnecessary for a 48v contactor.

2. I am using my ATV in the mountains occasionally to haul wood, But I also want to have some fun, so I'm not looking to go at a crawl. If you could help me determine what ratio I would precisely need I don't know how to cancel it in regards to my specific build and motor.

3. Do you have any sources I could use for reference for my wiring

4. What kind of wire should I be using and what is the suggested method of motor mounting? A transmission plate?

Thank you so much for the help!
 

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1. I was told that a pre-recharge resistor was unnecessary for a 48v contactor.

2. I am using my ATV in the mountains occasionally to haul wood, But I also want to have some fun, so I'm not looking to go at a crawl. If you could help me determine what ratio I would precisely need I don't know how to cancel it in regards to my specific build and motor.

3. Do you have any sources I could use for reference for my wiring

4. What kind of wire should I be using and what is the suggested method of motor mounting? A transmission plate?

Thank you so much for the help!
1. Bad advice. You'll burn contacts and weld contactor.

2. Uphill is even worse for low (numerical) ratio. Get at least nominal RPM for motor at 48V. Divide by GR. Gives wheel RPM. Times tire circumference gives distance per minute. Times 60 minutes/hour gives distance per hour. Convert to miles per hour and report back.

3. Use google to find Curtis manual for 1205.

4. For battery and motor power circuit I recommend welding cable. Plenty of discussions in forums about sizing. Off hand, I'd #6, but really like #4. Small vehicle so cost and weight difference is minimal.... #4.

major
 
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