Solenoid(contactor) limiting amperage?

scottginfla · 02-18-2012, 12:55 PM

Just wondering if solenoids are limited to their respective amperage rating or will they flow more amps, for example, a stock 48 volt albright solenoid I think is rated @ 250 amps, would a 500 amp controller be able to pass all its voltage through a 250 amp solenoid? I under stand that if so eventually the solenoid will fail due to overheating/over voltage.

Reason I ask is the solenoid is the last component to be upgraded on my cart, so was wondering if any gains will be had by putting in a 400 amp solenoid(thanks scottyb

) verses the stock unit.

Going to install the bigger solenoid more for piece of mind, so I don't get stranded 3 miles from camp with a toasted stock solenoid. Just wondering if I have been limiting my system all this time using the stock unit?

ForBruce · 02-19-2012, 02:10 PM

Quote:

Originally Posted by scottginfla

Just wondering if solenoids are limited to their respective amperage rating or will they flow more amps, for example, a stock 48 volt albright solenoid I think is rated @ 250 amps, would a 500 amp controller be able to pass all its voltage through a 250 amp solenoid? I under stand that if so eventually the solenoid will fail due to overheating/over voltage.

Reason I ask is the solenoid is the last component to be upgraded on my cart, so was wondering if any gains will be had by putting in a 400 amp solenoid(thanks scottyb

) verses the stock unit.

Going to install the bigger solenoid more for piece of mind, so I don't get stranded 3 miles from camp with a toasted stock solenoid. Just wondering if I have been limiting my system all this time using the stock unit?

as contacts heat up in a contactor / solonoid (by drawing over the contactor's rating ) the metal usually brass or copper begins to turn color. In the red hot stage the metal itself changes in charactistics and gets somewhat brittle (green or black).
At the same time it will not pass enough amperage and the contact's shape also distorts.
This is also true for the wire connected to these terminals. Sometimes you will see the tell tale signs showing burnt insulation 1 to 2" out of the contact point.

this burnt portion of wire must be trimmed back or replaced. And the bakerlite insulation on the contactor must be inspected for loose terminals caused by melted bakerlite

scottyb · 02-19-2012, 02:24 PM

The key is the controller limits, They can only pass their full capacity for seconds, not minutes. And a 2 minute rating would be much less and sustained delivery is somewhere near 50% (varies by make & model) The HD 200 I sell (in 36 or 48v) will take 200a continuously and 800a peaks. The super-duty 400a unit I sell has silver oxide contacts. It will handle 1000a inrush or peak and the full 400 continuous. I do favor the bigger one for the larger contact areas and better materials but, I don't think either one of these solenoids is going to leave you stranded with the typical 500a controller.

ForBruce · 02-19-2012, 02:36 PM

scottginfla..... scotty's not far off...

the high load is usually on take off but then it tapers down to about 175-250 amps. which is only 50 amps off from your unit.

why not run the cart for about 10-15 minutes and then with your hand feel the solonoid for excessive heat...

if none keep it.... if hot buy scottyb 400 amp model...

BTW: i have a 500 amp controller with a 400 amp solonoid. but me i like over kill

......... also : i have a 400 amp fuse in line with the batteries that never has blown
even with 500 amp controller..

scottginfla · 02-19-2012, 02:54 PM

Thanks guys, I was just concerned that the stock solenoid was the weak link in the system, and possibly I was not seeing the systems full potential.

02-18-2012, 12:55 PM	#1
scottginfla 72 volt torque monster Join Date: Dec 2009 Location: Sorrento, FLA Posts: 589	Solenoid(contactor) limiting amperage? Just wondering if solenoids are limited to their respective amperage rating or will they flow more amps, for example, a stock 48 volt albright solenoid I think is rated @ 250 amps, would a 500 amp controller be able to pass all its voltage through a 250 amp solenoid? I under stand that if so eventually the solenoid will fail due to overheating/over voltage. Reason I ask is the solenoid is the last component to be upgraded on my cart, so was wondering if any gains will be had by putting in a 400 amp solenoid(thanks scottyb ) verses the stock unit. Going to install the bigger solenoid more for piece of mind, so I don't get stranded 3 miles from camp with a toasted stock solenoid. Just wondering if I have been limiting my system all this time using the stock unit?

02-19-2012, 02:24 PM	#3
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,399	Re: Solenoid(contactor) limiting amperage? The key is the controller limits, They can only pass their full capacity for seconds, not minutes. And a 2 minute rating would be much less and sustained delivery is somewhere near 50% (varies by make & model) The HD 200 I sell (in 36 or 48v) will take 200a continuously and 800a peaks. The super-duty 400a unit I sell has silver oxide contacts. It will handle 1000a inrush or peak and the full 400 continuous. I do favor the bigger one for the larger contact areas and better materials but, I don't think either one of these solenoids is going to leave you stranded with the typical 500a controller.

02-19-2012, 02:36 PM	#4
ForBruce Mr. Helper Join Date: May 2009 Location: NY Catskills & South carolina Posts: 445	Re: Solenoid(contactor) limiting amperage? scottginfla..... scotty's not far off... the high load is usually on take off but then it tapers down to about 175-250 amps. which is only 50 amps off from your unit. why not run the cart for about 10-15 minutes and then with your hand feel the solonoid for excessive heat... if none keep it.... if hot buy scottyb 400 amp model... BTW: i have a 500 amp controller with a 400 amp solonoid. but me i like over kill ......... also : i have a 400 amp fuse in line with the batteries that never has blown even with 500 amp controller..

02-19-2012, 02:54 PM	#5
scottginfla 72 volt torque monster Join Date: Dec 2009 Location: Sorrento, FLA Posts: 589	Re: Solenoid(contactor) limiting amperage? Thanks guys, I was just concerned that the stock solenoid was the weak link in the system, and possibly I was not seeing the systems full potential.

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