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Unread 10-30-2010, 04:37 PM   #1
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Default Wtf just happened?

First, Specs in my signature so check there...

I go out get on the cart, turn the key on, flip the toggle to reverse, buzzer comes on press the throttle to back out and the cart lurches about 8 inches dies completely and starts smoking seriously bad, fear of fire wife goes to get the extinguisher while I disconnect power, and it continued to smoke after that. It was an Alltrax DCX500. Never had any issues with anything just happened like that... Nearly caught the cart on fire in fact I think I had flames for a bit.....

Starting the tear down now.
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Unread 10-30-2010, 04:40 PM   #2
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Default Re: Wtf just happened?

Loose battery connection or shorted connection.
Do you have the battery bank fused?
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Unread 10-30-2010, 04:52 PM   #3
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Default Re: Wtf just happened?

Quote:
Originally Posted by dougmcp View Post
Loose battery connection or shorted connection.
Do you have the battery bank fused?

Yes to the fuse and NO nothing at all is or was loose. Everything has lock nuts and lock tite. This smells of total controller failure.

i will test the motor first before adding another controller just in case there is a short there.
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Unread 10-30-2010, 04:57 PM   #4
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Default Re: Wtf just happened?

A shorted motor should take out the fuse so it's sounding like a controller meltdown.....weird.
Testing the motor is a good plan.
I would give Alltrax a call on Monday and see if they have some ideas.
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Unread 10-30-2010, 05:07 PM   #5
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Default Re: Wtf just happened?

Sorry about the cart, but I have an idea.
Its Holloween and have you ever made azboo mad?

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Unread 10-30-2010, 05:28 PM   #6
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Default Re: Wtf just happened?

Motor is good, the controller is smoked~
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Unread 10-30-2010, 05:30 PM   #7
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Default Re: Wtf just happened?

I take it the fuse didn't burn... what size & type is it?
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Unread 10-30-2010, 05:33 PM   #8
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Default Re: Wtf just happened?

Was everything working OK before this and nothing had been done to any wiring, batterys, etc in last few days that could be cause of melt down? I dont understand why fuse didnt blow saving some on controller damage? Was all damage done INSIDE CONTROLLER rather than at connections outside? Are you running a higher than 250 amp fuse and I hope its not a 500 amp fuse because of controller rating? Local none dealer EXPERT CART SHOP feels that fuse should have higher rating than max on controllers? A local cart running on beach burned down to the sand by having too high amp rated fuse, updates to cart were 600 amp Logistic controller, high HP motor, 1 gauge welding wiring, 650 amp fuse ( kept burning 400 amp fuses when sand dune climbing ), HD F&R control, Etc. HIS GREAT IDEA "THE HIGHER RATED THE FUSE THE BETTER MORE POWER"??? NOW NO CART, NO INSURANCE, AND fighting with ( DEQ ) about contamination to beach sand???? DEQ wants hazardous waste people to do clean up of sand and beach water pool at huge amounts of pesos? Very expensive fuse HUH in his case?
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Unread 10-30-2010, 06:02 PM   #9
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Default Re: Wtf just happened?

Scotty - Fuse did not blow it is the standard fuse that comes from AllTrax for 500amp plus controllers so it is CNN400.

OLDMEC - Nothing has been done to the cart, it has been working wonderfully, no issues. And as you guys know I do this as a side business as well, everything was completely tight and pristine, no corrosion, no changes, no loose cables. I haven't drove the cart for about a week.

This was a complete controller failure for some reason. I am suspect it was the PDPlus adapter that went bad and took out the controller, on the PD PLUS adapter between the big black connector and the place where it slides over the pins is a black capacitor and resistor this is where the smoke and fire was.

I have several of these adaptors, put another one and it started to smoke too..so it could be the controller.

This was a complete melt down of the controller as there was no major load, I just put it in reverse, barely touched the pedal and up she went.

I do have a new DCX400 that I just installed with a new PDPlus adapter and the runs great.


Guess I'll be calling Alltrax and my buddy will have to wait for the DCX400 that I was going to give him.
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Unread 10-31-2010, 01:09 PM   #10
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Default Re: Wtf just happened?

So now after all this, the charge cycle gets to 2 amps and won't shut off....

I sure as hell hope the controller didn't affect the OBC. It'll get to 57.5 and stop.
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