RXV not working after Controller Upgrade

[kgsc]

With key on is there pack voltage at the two small terminals on the solenoid?

[PingEye3]

I still say it is your solenoid.

IMHO It was probably 'on the verge' before you sent your controller to Bob. The pitted contacts in the solenoid now have had time to corrode and get even worse without any use over a week and a half during controller programming. Plus, the controller is asking for more thru the solenoid after the Bob touch.

[Jm91rs]

Voltage at the smaller terminal connected to red wire (key+ I think?), it stays ~48v, does not decrease like the large terminal to b+. I assumed the other terminal was ground. I’ll check that terminal in the AM. Ordered a solenoid today, they will allow me to return it if that is not the problem.

[Jm91rs]

Pack Voltage at both small terminals on the solenoid. The terminal going to B+ controller is the only one that's draining. It resets when the key goes off and then back on, but drains again quickly.

[kgsc]

Okay just to validate, put one lead on a small terminal and put your other lead on the other one. Does that give you pack voltage when the pedal is pushed? If so I am going with a bad solenoid as well.

[PingEye3]

Once it is confirmed that the solenoid has energized, there should be pack voltage on the controller side of the solenoid. Any voltages lower than pack voltage, replace it. It can only be voltage dropping across the contacts of the solenoid.

[Jm91rs]

I’ve been using pack - as my ground on these tests. I will check putting leads on the smaller terminals to see voltage, but using battery ground 3 of the 4 read pack voltage.
Replaced the solenoid today, same symptoms. The solenoid terminal headed to b+ controller is draining from 48+ to zero every time the key cycles back on.

[davidgolfer]

I had a similar issue with cart not moving. Replaced solenoid and it is working

[Jm91rs]

Unfortunately the new Solenoid did not do it for me.

[BobBoyce]

I put your controller on the bench.

List of old errors that I had cleared before I reprogrammed it.

Error Recorded
--------------------------------
Throttle Wiper
EM Brake Failed to Set
Stall Detected
Buzzer Driver Off
EM Brake Coil Missing
Main Coil Missing
Throttle Zero Check
Supervisor Watchdog
--------------------------------
These errors did not re-occur.

New errors that were recorded after I mailed the controller back.

Error Recorded
-----------------------------------------------------------------------------------
Main Contactor Welded - It really has/had a bad solenoid!
HPD/Sequencing Fault--- Turning key on with a pedal not fully up
Controller Overcurrent---- Reads too much current draw, even when there is none.
Supervisor Comms-------- An error indicator
-----------------------------------------------------------------------------------
Controller Overcurrent is a persistent fault, and it re-occurs each time the controller is powered on. This would be considered a fatal error. FSIP could likely repair it, but you might spend more by having it repaired vs just buying a controller from them on eBay.

https://www.ebay.com/itm/152355026624

Bob