C124 Silver Box mystery

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holmesjtg
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C124 Silver Box mystery

Hi all,

I was wondering if anyone can tell me what the silver rectangle box that sits on top of the battery pack is for. I'm having one or two issues that may or may not be related. The first is that I'm losing power to the motor although the lights remain on. The indicator lights suggest a malfunctioning temp sensor because the battery is cold (4 long and 2 short flashes). But the other thing I've noticed is that the connector to the silver box is shorting when I wiggle it - even with both the winter switch and main breaker off. I'm assuming this might be a capacitor of some sort but if anyone has seen something similar or has some advice, I'd really appreciate it!

This is on my C-124 (3 years old now with just over 10k on it).

Cheers,
Jeff

Solar Steve
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Re: C124 Silver Box mystery

That box is likely the 24 volt converter without which the main computer stops and that cuts everything. I had one fail last year and it was replaced. At first it was intermittent, with that connector pop you noticed. Immediately remove the connector and older the wires to eliminate. As I tested and was just discovering the source of the pop noise, the effect of repeated intermittent killed the 24 volt converter. It stopped for good rather than intermittent. So avoid making that arc, and try patching the 3 wires by soldering. If it has quit altogether, then you need a new converter. You will find it almost impossible to physically remove the old one from that space, but the new one did fit in on top of it without much hassle.

Anyway after getting that resolved I sold the scooter, just forgot to opt out of the Current motor list, lucky because that showed me your post on the same problem.

Solar Steve
Off Grid Photovoltaics
in North Idaho

PJD
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Re: C124 Silver Box mystery

I believe that the 24V converter is also a power supply for the Kelly controller. It is attached to the base of a "C" shaped bracket that is attached to the battery pack bands. the upper part of the "C" holds the BCU microcontroller and the 12 volt (actually 13.5 volt) DC-DC converter both mounted in the same enclosure. It requires quite a bit of body dis-assembly to get to it. I'd be careful about mounting it on top of the old box because it will restrict air flow to the heat sink fins to the 12 volt converter.

The original test pilot scooters were assembled without much thought as to serviceability. I have easier access because I removed that flat glued down deck under the seat and built a removable, expanded under-seat storage compartment to take advantage of all the space not used by the extra cells in the 24-cell version, plus it provides access to the BCU/DC-DC-converter. I also removed and remounted the BCU/DC-DC converter further forward on the "C" bracket (rearward w respect to the scooter) for easier access to connectors (I'll get a wiring diagram someday I hope!) and better cooling of the DC-DC converter. Finally I glued a small piece of wood between the BCU enclosure and the 24 volt converter enclosure becasue it would vibrate on the light-gauge "C" bracket rather severely.

The little niggling design problems seemed to be almost endless for the first year or so, but everything seems to be finally solid and reliable now.

Current supposedly only makes a 24 cell version now. They also mount the BCU and DC-DC converter separately because in hot climates the heat was damaging the BCU.

holmesjtg
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Re: C124 Silver Box mystery

Thanks guys for your thoughts. I'm in touch with Current about it and will report back what happens. The box actually came loose on mine so access became a bit easier... :-)

Jeff Holmes
Wheels: Current Motor Co C124
Work: Encyclopedia of Life www.eol.org

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