1992 DS wiring issue

Shawn8202

I have converted by 36v DS to a 48v system thanks to scottyb's complete conversion kit including all new 2ga cables.

I have spent a ton of time making sure each wire was correct, new ends if not new wires all together. Checking the current with a new volt meter, confirming battery pack voltage and this is what I have going on....

If the diode and resistor and NOT hooked up, I get a click at the solenoid and 1 green + 6 red lights at the controller. According to Alltrax, this error code is a "pre-charge Failure". If I hook up the diode and resistor, I get a puff of smoke from either the solenoid or the resistor.

I am getting 50.5 volts solenoid, key switch, Vglide and again, the solenoid is clicking when the gas pedal is pressed.

Has this ever happened to anyone and if so, what was the fix?

Let me also add that ScottyB spent a ton of time speaking with me over the phone, going over each wire and many emails. Hard to ask for better service than that!!

I have attached a few photos for your review but please note: The + and - charger wire are now on the main + and - terminals.

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BGW

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Shawn8202

So Alltrax had me move all wires from one large terminal of the solenoid to the other in order to test to see if the solenoid was bad. . I did this and almost burnt my house down. The main + cable end literally disintegrated when I touched it to the #1 battery +terminal.

I put a new terminal on the end of the main battery + cable and +charger cable and I am back to square one. 1 green and 6 red blinks.

Sergio

Be careful as the amount of energy on those batteries can be very dangerous on a shorting situation.
From the symptoms you described it would appear you have a short in those 2ga cables.
I don't have any experience with those conversion kits, but assuming at the end you are going to end up with a system like the one on the sticky for the 92 solid state wiring...
I would guess the problem is with the negative battery cable that goes into the Alltrax controller. The only other wire sharing that same connector should be a small gauge wire going into the coil side of the solenoid. If you have a 2ga cable from that connector to the F&R switch, that would be a problem.
Double check all of the 2ga cables going into the controller and F&R switch.
The bad news is most likely the meltdown you experienced has already happened inside the solenoid contactor the first time it turn on. The good news is that the controller appears to still be working.
Good Luck.

Shawn8202

Thank you for your thoughts. I am working with Alltrax and ScottyB to solve the issue but needless to say, I am extremely frustrated.

On a side note, I can now truly appreciate the power of a 48v system. It literally blew up in my face but luckily, I did not get burned.

Fingers Crossed !!


Shawn

Xact1

Shawn, sorry to see you are having some issues. LMK if I can be of any help. I agree that it appears that you have a short situation.

Shawn8202

Thank you for the message Xact1. Per Alltrax, it is a bad controller. So the bad one goes back and a new one should fix the issue. Fingers crossed!!!


Shawn

Xact1

Alltrax is a great company to deal with. I hope that this is covered under warranty.

Shawn8202

I could not be happier with ScottB and Alltrax. Both have spent a great deal of time with me on the phone and with countless emails. Two VERY good companies to work with.

Alltrax indicated this is an absolute warranty issue. THANK GOD!!


Shawn

Xact1

SO, I would assume that someone provided an instruction on how to bypass the controller in ordrer to confirm that everything else was OK?

Shawn8202

Well ... I will do my best to describe how it went...

We checked the voltage at a bunch of different places and in different combinations. With all cables and wires in the proper place and the pedal pressed, I would get the same 1green/6red blinks from the controller. The tech had me place all wires on one side of the solenoid. Boom ... the cart would move forward and back and with a solid green light on the controller. When all wires were returned to their proper place, the same 1green/6 red indication would happen on the controller. This is when the tech determined that the controller was bad.

From what I have read, if you place all wires on one side (Large terminal) of the solenoid (Bypass the solenoid) and the cart runs, you have a bad solenoid. But who am I to argue with the tech!!!!!
Thoughts ...