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Unread 06-17-2014, 06:20 PM   #1
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Default Dead short re-connecting battery cables

I have a '07 TXTPDS Ser.#2496279,

It was functioning with no issues, I needed to do some welding on the frame. I removed the B+ cable and two other smaller wires then zip tied them together so not to get them mixed up, I then removed the B- cable and two smaller wires and zip tied them. None of these wires touched a ground source, Disconnected a smaller wire at the center of the battery bank towards the rear of the cart. That left the bank of batteries just sitting there.

I performed my welding job and now when I try to re-connect the B+ and B- with no other wires I have a dead short (bad arch), I put my multimeter between the B+ and B- cables and there no continuity (open circuit).

Can anyone shed some light on what happened ?

Thanks,

Rob
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Unread 06-17-2014, 06:31 PM   #2
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Default Re: Dead short re-connecting battery cables

Might not be a short. I would check your precharge resistor on the solinoid. If it is bad the battery cable will spark when connected to the battery.
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Unread 06-17-2014, 06:44 PM   #3
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Default Re: Dead short re-connecting battery cables

Flip the run tow switch into the tow position before disconnecting or reconnecting any part of the electrical system. If not you may damage the controller. (small chance) The 'short' you think you see is actually a high amp draw.
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Unread 06-17-2014, 06:49 PM   #4
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Default Re: Dead short re-connecting battery cables

I hope you had the "tow/run" switch set in the "tow" position before disconnecting your batteries! You may have damaged the speed controller if not. If you didn't do this, set it to "tow" and try reconnecting the cables.
Edit: Scott, you beat me to it! :)
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Unread 06-17-2014, 07:00 PM   #5
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Default Re: Dead short re-connecting battery cables

Thank's a bunch guy's, I'll give it a try in the am when I return to the shop....
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Unread 06-18-2014, 08:53 AM   #6
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Default Re: Dead short re-connecting battery cables

If the battery pack has been disconnected from the controller for more than a few minutes, you will get a significant arc when your reconnect the pack.

The controller contains a bunch of filter capacitors that discharge when the pack is disconnected. Normally, they are kept charged by the pre-charge resistor across the solenoid contacts. The arc you see is what the solenoid contacts would see if not for the pre-charge resistor.

If you tried measuring between the battery pack's B+ and B- cable with an ohmmeter, you probably need a new meter.
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Unread 06-18-2014, 08:56 AM   #7
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Default Re: Dead short re-connecting battery cables

LOL -You can use another resistor to precharge the control by holding it between the battery cable and the battery post for about 30sec+ before making the connection.
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Unread 06-18-2014, 10:40 AM   #8
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Default Re: Dead short re-connecting battery cables

Quote:
Originally Posted by scottyb View Post
LOL -You can use another resistor to precharge the control by holding it between the battery cable and the battery post for about 30sec+ before making the connection.


I use a 10k resistor, but most anything will help.

That spark scared the daylights out of me the first time I reconnected my battery pack.

I probably spent half an hour checking and rechecking things before I figured out what was happening.
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Unread 06-18-2014, 11:02 AM   #9
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Default Re: Dead short re-connecting battery cables

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Originally Posted by JohnnieB View Post


I use a 10k resistor, but most anything will help.

That spark scared the daylights out of me the first time I reconnected my battery pack.

I probably spent half an hour checking and rechecking things before I figured out what was happening.
I learned this trick when bench programming. Even with 18 or 21v the spark was strong and so I used a little inline resistor set up.
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Unread 06-18-2014, 11:03 AM   #10
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Default Re: Dead short re-connecting battery cables

Since most of us don't have spare resistors lying around, you can use a plain 120v 60watt (or so) incandescent light bulb to charge up the capacitors. It is an effective resistor! It's also useful to use as a "cart" test light when your dmm is somewhere else!
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