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Unread 04-26-2016, 07:56 AM   #1
Not Yet Wild
 
Join Date: Apr 2016
Posts: 4
Default Controller over heating on lifted Club Car

Controller on lifted Club Car overheats and shuts down. Goes again after waiting anywhere from 15 to 45 minutes. Occurs mainly after low speed use on hilly terrain. Has never died when running high speed on flat road. Controller & electric motor very hot to the touch when it stops.

What can be done to keep controller from overheating - change in controller configuration settings?, or replace/upgrade any of the cart components, etc?

Specifics -
Club Car, SN# = A0002, Model = DS Electric (1982-2000.5 version), Year built = 2000, 48V, Lift kit

Motor GE D380, Mod = 5BC49JB3071, HP = 4.0/5.5, RPM = 4150/5700, Volt = 36/48, AMP = 105/105, FR = 49, Wound = Series, Amb = 40, Time Rating = Cont, Insl Class = H, Installed in Cart Jan 2011

Batteries - Trojan 8V T-875, Installed new in Feb 2014.

Controller Alltrax, Current Limit of 500A,
Controller Model = AXE4855, Field Map# = 96,
Switches High Peddle Disable = no check mark, Plug Break = no check mark, Turbo = no check mark, and Speed Reverse with a check mark. Settings Max Output Current = 100%, Under Voltage = 24.0 Volts, Over Voltage = 58.0 Volts, Throttle up Rate = 1, Throttle Down Rate = 3, Brake Current = 0%, Top Speed = 100%,
Throttle Sensor Type = Club Car 5K 0, Throttle Response = Progressive

Solenoid - White Rodgers, Type = 586-120111, Contact Rating = 200 Amps, Inrush = 600 Amps

Cables all 4 Gauge, all firmly attached/tightened, no corrosion.
Diode 3 Amp
Resistor 10W 470 ohm JW
F&R Switch Heavy Duty, High Amp
Tires 22 Mud Busters, aggressive off-road (22 x 11.00

Thanks!
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Unread 04-26-2016, 08:24 AM   #2
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Default Re: Controller over heating on lifted Club Car

Where is the controller mounted? Can you provide it with better air circulation and/or can you provide it with a better heat sink? Be sure it is mounted tightly to a solid metal surface such as Alum to function as a heat sink...
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Unread 04-26-2016, 09:24 AM   #3
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Default Re: Controller over heating on lifted Club Car

It is tightly mounted at the original location to a metal alum sheet. Are there any add on heat sinks available made for this purpose, or any ideas on how to increase air flow? Also, will going from 4 gauge to 2 gauge cables help any? Tks
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Unread 04-26-2016, 09:44 AM   #4
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Default Re: Controller over heating on lifted Club Car

Quote:
Originally Posted by Fields Farm View Post
... will going from 4 gauge to 2 gauge cables help any? Tks
Not going to hurt but it will not offer much if any by the way of help... 4 gauge cables are plenty big enough for a 500 amp build. I went with 2 gauge simply as I bought the cart with OE cables and it was but another 20 bucks to build 2 over 4 gauge... I do notice that my back plate gets pretty darn hot when we take the cart out for long slow rides in our hilly hood...
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Unread 04-26-2016, 11:10 AM   #5
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Location: Southern California
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Default Re: Controller over heating on lifted Club Car

Is the environmental cover install over the controller?
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Unread 04-26-2016, 03:40 PM   #6
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Default Re: Controller over heating on lifted Club Car

No. There is no environmental cover over controller or solenoid.
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Unread 05-02-2016, 11:56 AM   #7
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Default Re: Controller over heating on lifted Club Car

Alltrax tech support believes that as the controller warms up, a solder joint within the controller is losing connection causing the controller to fail at about 65 C degrees, versus the normal thermal shutdown of 95 C degrees. They indicate not repairable, and should be replaced. Any suggestions on what make/model of controller would work the best with the existing GE D380 motor, and support traveling over hilly terrain, sometimes at a slow rate?
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Unread 05-02-2016, 01:53 PM   #8
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Default Re: Controller over heating on lifted Club Car

I believe the new SRX controls just came out from Alltrax. They seem to be the twin of the XCT for sepex carts. That's what I would put in it.
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