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Old 04-25-2009, 06:08 PM   #1
dbms95
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Default Big Problem with batteries

Went to hook up my new batteries after putting in the new 48v seloniod and axe controller and I guess I wired it wrong. It threw sparks and melted the end of the cable. I am not sure where I went wrong so if anybody sees something I did wrong please tell me, I am just hoping I havent screwed something up. When you are wiring the batteries is there a specific order that you should do?
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Old 04-25-2009, 11:03 PM   #2
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Default Re: Big Problem with batteries

So nobody has any ideas or suggestions?
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Old 04-26-2009, 12:46 AM   #3
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Default Re: Big Problem with batteries

and your positive you have 48volts at your 2 main cables going to solenoid/controller, also do you have a diode and resistor on your solenoid, prevent feed back and pre charge and so on, did you wire your cart off of a diagram from alltrax, i think they got a diagram section on there site, and lastly where did you get the controller,
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Old 04-26-2009, 07:29 AM   #4
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Default Re: Big Problem with batteries

I can't see anything in the pictures you posted that would cause that? Wierd that the fuse at the controller didn't melt first? Like bhfear said check your battery connections and pack voltage. Then check the voltage on the burnt cable ..... there is positive and negative cables at the controller. get the diagams out and make SURE you have not switched them.

It is kinda odd that the fuse at the controller didn't burn first..... Is that on the pos or neg? and which polarity was the last connection you made?
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Old 04-26-2009, 07:38 AM   #5
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Default Re: Big Problem with batteries

I ordered everything from EV Drives, but it came directly from Alltrax. At this point I am not sure of anything, thought I was correct in my wiring, but I guess I wasn't. I do have the diode and resistor on the solenoid, but I didnt get a diagram from the company, just a brochure that says what the names of the controller terminals, and nothing about solenoid, so I used diagrams from here to do it and the one from alltrax's website to the best of my ability.
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Old 04-26-2009, 07:40 AM   #6
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Default Re: Big Problem with batteries

what does your voltmeter tell you? Can you check polarity?
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Old 04-26-2009, 07:45 AM   #7
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Default Re: Big Problem with batteries

The fuse is on B- on the controller and it was the connection on the battery side I was making when it sparked. I am not to where I can check it I am away from the house until this afternoon, going to nephews first communion, bad if I missed it to work on golf cart.
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Old 04-26-2009, 07:54 AM   #8
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Default Re: Big Problem with batteries

So......how big is that fuse? You mean to say that it was on the other end of the melted cable?
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Old 04-26-2009, 08:05 AM   #9
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Default Re: Big Problem with batteries

yea its on the controller side of that cable, B-. Its a 400 amp fuse rated for 450A-650A.
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Old 04-26-2009, 08:12 AM   #10
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Default Re: Big Problem with batteries

Well we now know that the end of a cable is a smaller fuse than 400 amps .... I have run the same conversion with as little as 175 amp fuse.....
You haven't shown or told us anything yet that would raise a red flag. You are just going to have to very carefully review the diagrams you have and check and recheck!
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