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Unread 07-05-2011, 05:45 PM   #1
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Default Controller super hot, cart shutting down

Over the weekend I had some problems with the cart, we were at a huge park, a lot of long rides, 1/4-1/2 throttle some long full throttle. A few times the cart would just quit after letting off the throttle and trying to start again, I got to looking around, all cables tight ect, but noticed the controller was so hot you could not hardly touch it GE 500/30 . Letting things cool down and everything was fine, but the controller and motor were super hot, along with the cables between the first two batts in the pack 8,16 volt ones, as you moved across the pack the cables became cooler as you reached the 48 vot batt in the pack, along with the wire off that batt going to the back.

All batts show 8.63- 8.67 and the pack voltage is 51.7, trojan t-875.
the motor is a plum quick bandit and I have #2 cables everywhere.

So not sure what is causing things to heat up and shut down, any ideas as to where to go from here?

My initial thought was a low voltage problem, but that does not seem to be the case.
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Unread 07-05-2011, 06:15 PM   #2
The Last Moja Morani
 
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Default Re: Controller super hot, cart shutting down

thjat sounds like thermal shutdown ( controller ) but what concerns me is the heat.....is cart running now?.................................
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Unread 07-05-2011, 06:25 PM   #3
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Default Re: Controller super hot, cart shutting down

Yes cart running fine, like I said once cooled down ran normal, also remember the ground wire running through the OBC was pretty hot too.

There is slight corrosion on the wires going across the first two batts in the pack, same wires that were hotter than the others.

Heat is right, why is the contolller, motor and some wires getting so hot and other wires not?
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Unread 07-05-2011, 06:26 PM   #4
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Default Re: Controller super hot, cart shutting down

you could try swapping battery positions to see if the heat follows those 2 batteries. repeat the same process for the wires. process of elimination until you find the culprit.
-sj
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Unread 07-05-2011, 06:28 PM   #5
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Default Re: Controller super hot, cart shutting down

I say bad connections or bad batteries
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Unread 07-05-2011, 06:30 PM   #6
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Default Re: Controller super hot, cart shutting down

I will go out and do a load test on the pack and on each batt.
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Unread 07-05-2011, 06:59 PM   #7
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Default Re: Controller super hot, cart shutting down

I load tested each batt three times

First test all held just above 8 volts doing a 10 sec load

Same on the second test

Third test the # 5 batt dropped to 7.8 volts
that could be because i tested them each three times within a very short period of time

I did not test each batt three times in a row, but went across the pack one batt at a time then started over, cables disconnected from each other.

Could not do a pack test cause my mechanical load meter only goes up to about 15 volts.
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Unread 07-05-2011, 07:06 PM   #8
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Default Re: Controller super hot, cart shutting down

OK now your at connections I feel no heat in any of my battery leads none!!!
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Unread 07-05-2011, 07:10 PM   #9
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Default Re: Controller super hot, cart shutting down

Label and move the cables around. This will locate the problem.
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Unread 07-05-2011, 07:17 PM   #10
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Default Re: Controller super hot, cart shutting down

Ok, so you think I have a couple bad cables in the pack?
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