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Unread 12-10-2014, 07:32 PM   #61
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Default Re: Couple of wiring questions.

Quote:
Blue/White to the solenoid will only flip from positive to negative 48V if all positive connections are solid
Not quite, the Blue/White wire will complete the connection to negative if everything is working properly. Think of it like a on/off switch.

Quote:
Right now, its doing the reverse. Its 6v positive with the key on and 48v negative with the key off. Exactly backwards
How exactly are You doing these readings?
Where are the voltmeter probes connected to?
Is the diode connected to the solenoid and the solenoid connected to the bad controller?

The MCOR readings You have are not right, actually I am not sure how you can get the readings you have.

If You definitely had the 3 pin plug unplugged from the MCOR and took those readings at the MCOR itself, I would replace it before plugging in the new controller.

At the very least, the 20Ω max resistance from Yellow to Purple would translate to less than 1% throttle input, way too low to cause the controller to close the solenoid anyway.
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Unread 12-10-2014, 07:52 PM   #62
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Default Re: Couple of wiring questions.

How exactly are You doing these readings? I have a test light that shows voltage 6, 12, 24, 45. + or -. So Key on I clip black to Neg and point to wire and it shows 6v +. When I turn the key to off, I clip it to the positive lead on battery and the point to the wire and It shows 48v-.


Is the diode connected to the solenoid and the solenoid connected to the bad controller? The solenoid is connected to the bad controller. I have a resistor on the solenoid. Diode?


The MCOR readings You have are not right, actually I am not sure how you can get the readings you have. Ill retest per your instructions.

Im learning here. I don't mean to be frustrating.
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Unread 12-10-2014, 08:47 PM   #63
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Default Re: Couple of wiring questions.

This is the diode, right? Came with the solenoid.


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Unread 12-10-2014, 09:15 PM   #64
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Default Re: Couple of wiring questions.

Can you post a photo of your test meter?
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Unread 12-10-2014, 09:37 PM   #65
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Default Re: Couple of wiring questions.







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Unread 12-10-2014, 09:48 PM   #66
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Default Re: Couple of wiring questions.

I think it would be better to use the other meter for testing on the cart. That's just me. The other one is for quick test check for presents of voltage and give you a quick check.
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Unread 12-10-2014, 09:51 PM   #67
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Default Re: Couple of wiring questions.

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Originally Posted by mrgolf View Post
I think it would be better to use the other meter for testing on the cart. That's just me. The other one is for quick test check for presents of voltage and give you a quick check.
That is what I use it for. Tells me if I have 12, 24, 48v + or -.. Not too complicated.

I mostly use the ohm meter..
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Unread 12-10-2014, 10:05 PM   #68
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Default Re: Couple of wiring questions.

Yes that is the diode in the picture. The positive (blue wire) goes to the terminal where the striped end of the diode is connected, which is also indicated with the + on your solenoid.

I don't know the specs on that test light, I would just stick with the digital voltmeter.
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Unread 12-10-2014, 10:23 PM   #69
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Default Re: Couple of wiring questions.

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Originally Posted by Sergio View Post
Yes that is the diode in the picture. The positive (blue wire) goes to the terminal where the striped end of the diode is connected, which is also indicated with the + on your solenoid.

I don't know the specs on that test light, I would just stick with the digital voltmeter.
That's where the Light blue from the key is connected +. The Blue/White #12 from the controller is on the left. Right now, as weve discussed, I have a 48v negative running from the neg on the end battery running straight to the left side. When I turn the key to "on", the solenoid clicks as it should.

When testing the Blue/White #12. Key on. I get +6v, I turn the key off, I get -48v. That is the opposite of what its supposed to do. There's a link from another thread that states this wire is +6v with key off and switches to -48v with the key on, thus allowing the light blue (key switch on) to activate the solenoid.

I was just wondering how it could be swapped.
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Unread 12-11-2014, 08:36 AM   #70
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Default Re: Couple of wiring questions.

I am not sure what thread or what the pre-conditions were needed for those test results.

As a general troubleshooting method, let me make the following statement:

No valid measurements or conclusions can be made on a non-energized circuit.

(to avoid split hair arguments with other technical folks, I am specifically referring to "quantitative" not "qualitative" results)

The proper way to test the solenoid (assumes a diode is properly installed across the solenoid coil):
  • Set the meter to 200vDC
  • Positive probe on positive side of Solenoid coil.
  • Negative probe on negative side of solenoid coil.

Turn key switch on and press Pedal.

If You have +48v and solenoid does not engage:
Replace Solenoid.
If You don't have +48v:
Move the negative probe to pack negative.

If You have +48v:
Troubleshoot why controller is not providing a path to Negative
If You don't have +48v
Troubleshoot why +48v is not available to Solenoid.
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