DCS solenoid cable choke point ?

[gwsmith1]

I am in the process of upgrading to 48 volts on my DCS TXT. I upgraded the controller a couple of years ago to a XCT48400 and built new 1/0 cables in anticipation. I just got a SW200 solenoid from ScottyB and am in the process of swapping out the 180. Now taking a closer look I am thinking I missed a cable during the cable swap. Is the negatve cable on this solenoid a choke point ? Should this cable have been changed when I did all of the other cables ? This may explain my struggle to get more than about 20 mph ( on 22" tires) even with a 48v pack ? Of course that could be a motor issue at this point too. Any thoughts ?
Thanks !

[JohnnieB]

There are at least ten high amp cables in a DCS drive and all ten need to be replaced.

Five connect the battery pack, solenoid, controller and motor together and five connect the six batteries together. If more than six batteries are used in the pack, more cables will be needed.

All of the high amp cables form a series loop, so they all have to be the same gauge or the least of them will limit the ampacity of the high amp circuit.

[gwsmith1]

Originally Posted by JohnnieB

There are at least ten high amp cables in a DCS drive and all ten need to be replaced.

Five connect the battery pack, solenoid, controller and motor together and five connect the six batteries together. If more than six batteries are used in the pack, more cables will be needed.

All of the high amp cables form a series loop, so they all have to be the same gauge or the least of them will limit the ampacity of the high amp circuit.

Thanks for the clarification JohnnieB ! Looks like I missed one. Time to take a measurement and send ScottyB another order!

[JohnnieB]

Heat is the byproduct of the undesired resistance of smaller than needed cables and bad connections, so an inexpensive non-contact IR thermometer comes in handy.

Make a hard run (Lots of stops and starts and hills) and check the temperature of the high amp cables and connections. All should be within about 10°F of the air temperature and none of the cables or connections ought to be significantly warmer than the others.

It is normal for the solenoid, controller and motor warm up quite a bit, but nothing else in the drive system should.

[gwsmith1]

Originally Posted by JohnnieB

Heat is the byproduct of the undesired resistance of smaller than needed cables and bad connections, so an inexpensive non-contact IR thermometer comes in handy.

Make a hard run (Lots of stops and starts and hills) and check the temperature of the high amp cables and connections. All should be within about 10°F of the air temperature and none of the cables or connections ought to be significantly warmer than the others.

It is normal for the solenoid, controller and motor warm up quite a bit, but nothing else in the drive system should.

That would be an interesting test/troubleshooting tool. Looks like I get to add to my toy box.