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Unread 03-15-2017, 01:43 AM   #1
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Default Followup - TXT 36v fixed...but...

First, thanks to JohnnieB and Yurtle for the help in getting my new-to-me stock-as-a-rock 36v TXT going.

Here's the latest, which may help others. I replaced all the cables to the motor with new cables (4 gauge). After it was running properly, I decided to replace the stock battery cables with 1/0 welding cable. However, I have noticed that two of the motor cables get slightly warm (i.e., nothing approaching "hot," but slightly warmer than the others) after a run, so I am going to replace all the cables with the same 1/0. Given the "overkill" of the 1/0 battery cables, I would not have expected an issue with the just "slightly overkill" sizing in the motor cables, but ??? Yeah, I know - keep all cables in the circuit alike, but again, I would not have expected this, given that all cables were oversized, but it's late, so ??? The bottom line: if you are replacing cables (and if you have stock cables, that certainly cannot hurt), going oversized and alike seems to be the ticket.
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Unread 03-15-2017, 05:45 AM   #2
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Default Re: Followup - TXT 36v fixed...but...

Quote:
Originally Posted by JoeBleaux View Post
First, thanks to JohnnieB and Yurtle for the help in getting my new-to-me stock-as-a-rock 36v TXT going.

Here's the latest, which may help others. I replaced all the cables to the motor with new cables (4 gauge). After it was running properly, I decided to replace the stock battery cables with 1/0 welding cable. However, I have noticed that two of the motor cables get slightly warm (i.e., nothing approaching "hot," but slightly warmer than the others) after a run, so I am going to replace all the cables with the same 1/0. Given the "overkill" of the 1/0 battery cables, I would not have expected an issue with the just "slightly overkill" sizing in the motor cables, but ??? Yeah, I know - keep all cables in the circuit alike, but again, I would not have expected this, given that all cables were oversized, but it's late, so ??? The bottom line: if you are replacing cables (and if you have stock cables, that certainly cannot hurt), going oversized and alike seems to be the ticket.
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Unread 03-15-2017, 06:54 AM   #3
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Default Re: Followup - TXT 36v fixed...but...

Quote:
Originally Posted by JoeBleaux View Post
First, thanks to JohnnieB and Yurtle for the help in getting my new-to-me stock-as-a-rock 36v TXT going.

Here's the latest, which may help others. I replaced all the cables to the motor with new cables (4 gauge). After it was running properly, I decided to replace the stock battery cables with 1/0 welding cable. However, I have noticed that two of the motor cables get slightly warm (i.e., nothing approaching "hot," but slightly warmer than the others) after a run, so I am going to replace all the cables with the same 1/0. Given the "overkill" of the 1/0 battery cables, I would not have expected an issue with the just "slightly overkill" sizing in the motor cables, but ??? Yeah, I know - keep all cables in the circuit alike, but again, I would not have expected this, given that all cables were oversized, but it's late, so ??? The bottom line: if you are replacing cables (and if you have stock cables, that certainly cannot hurt), going oversized and alike seems to be the ticket.
YES this is a good idea.....mine are 2 ga. but the KEY, and you discovered this, is to ensure you have a matching set, everything the same size,
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Unread 03-15-2017, 07:53 AM   #4
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Default Re: Followup - TXT 36v fixed...but...

overkill is underrated by most-i am all for it!
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Unread 03-15-2017, 10:10 AM   #5
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Default Re: Followup - TXT 36v fixed...but...

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Originally Posted by Sir Nuke View Post
KEY is to ensure you have a matching set, everything the same size,
Amen to that, you all helped me with that about a month ago.
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Unread 03-15-2017, 12:55 PM   #6
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Default Re: Followup - TXT 36v fixed...but...

Ironically, the cables between motor and controller actually carry more current than the one connecting the batteries together and connect the battery pack to the controller when the PWM output of the controller is less than 100% duty-cycle.

The attached page for a Curtis 1204 manual explains this phenomenon and data logs from Alltrax controllers will verify it to be true.

For example, in a data log I made of a 10 minute test run after changing field maps, while the pedal switch was close and Forward selected, the average duty-cycle was 56%, the average battery current was 58.7A and the average armature current was 93.0A, so the cables on the battery side of the controller were only averaging about 63% of the amps carried by the cables on the motor side of the controller.

If anywhere, the overkill ought to be between controller and motor.

4Ga is the minimum size cables that ought to be used with any controller below 500A and 2Ga is minimum for 500A up to about 650A.
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