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Unread 03-27-2016, 08:56 PM   #1
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Default Could OBC have caused short in controller?

I have a 2009 club car DS IQ 48v on 30" tires. My set up was 500 dc alltrax, 200amp solenoid, pq bandit up grade. Had this setup issue free for 2 years....cart recently quit due to alltrax burning up, and found main contact on solenoid burnt(controller side) and resistor was smoking hot. My question is did the solenoid being undersized cause this? Why did my 400 amp fuse not blow? Could something with obc cause this? Motor pulling to many amp? Just don't want this to happen again
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Unread 03-27-2016, 09:03 PM   #2
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Default Re: Could OBC have caused short in controller?

I've ordered a new 400amp/1000 peak contactor, 2ga wire, new D&D torque motor(just because) and Alltrax is replacing controller under warranty. Just want to know if I should check anything else that could have shorted controller
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Unread 03-28-2016, 07:26 AM   #3
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Default Re: Could OBC have caused short in controller?

Any help/suggestions?
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Unread 03-28-2016, 07:44 AM   #4
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Default Re: Could OBC have caused short in controller?

How did you determine the controller was burnt up?
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Unread 03-28-2016, 07:52 AM   #5
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Default Re: Could OBC have caused short in controller?

Went through troubleshooting steps with alltrax, also the smell of it was very strong
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Unread 03-28-2016, 08:45 AM   #6
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Default Re: Could OBC have caused short in controller?

Quote:
Originally Posted by Courtlandjs View Post
I've ordered a new 400amp/1000 peak contactor, 2ga wire, new D&D torque motor(just because) and Alltrax is replacing controller under warranty. Just want to know if I should check anything else that could have shorted controller
I don't know the reason for your magic smoke being released but the OBC was not part of that release. The OBC is mainly in charge of just that, charging...

Just wondering if you had a properly sized pre-charge resistor across the big terminals of your solenoid? That can result arcing across the contacts if you don't?
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Unread 03-28-2016, 09:01 AM   #7
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Default Re: Could OBC have caused short in controller?

Yes I had the correct resistor, but my solenoid was only rated for 200 amps, I think somehow when it shorted it took the controller with it....the contact on controller side of solenoid was welded closed/shorted, I know it was not correct size solenoid for the controller, I think that may have been the initial cause.....
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Unread 03-28-2016, 09:32 AM   #8
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Default Re: Could OBC have caused short in controller?

Quote:
Originally Posted by Courtlandjs View Post
Yes I had the correct resistor, but my solenoid was only rated for 200 amps, I think somehow when it shorted it took the controller with it....the contact on controller side of solenoid was welded closed/shorted, I know it was not correct size solenoid for the controller, I think that may have been the initial cause.....
Sure an undersized solenoid once it started arcing would have caused increased resistance (resistance = HEAT) in its contacts and if your big motor was trying to draw big amps and your controller was trying to pass those big amps that were no longer available due to the failing solenoid heat would have been created and passed on to the man caught in the middle... That being your controller!
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Unread 03-28-2016, 09:55 AM   #9
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Default Re: Could OBC have caused short in controller?

Thanks teecro!! Thats what I'm thinking, I just wanted an outside opinion! I should be good now that Im upgrading to 2ga wire, and correct solenoid size, new controller, and new vented torque motor to handle the 30s
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Unread 03-29-2016, 05:59 PM   #10
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Default Re: Could OBC have caused short in controller?

Be sure you have Altrax send you the correct profile for the motor you install.

I am running the DCX 500 controller with a stock motor and Altrax emailed me a profile to limit the output of my controller to prevent killing my motor
I did however loss a 200 amp soleniod because it could not handle the amps and replaced it with Scottyb's 400 amp which included the correct diode and resistor
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