Problems with extended slow speed operation

[ClubCarCooter]

Thanks Scotty...

I reckon the aluminum plate it's mounted on is for heat sinking ability but mine may have a homemade blower added someday soon... there's plenty of room to play in there.

[mrgolf]

image.jpg


Photo of IQ controller

[ClubCarCooter]

Thanks MrGolf for the pic....

[camaroluvz28]

I figured after you got the access panel you would be able to see the controller, I'm with Scotty as well...if you gotta repair it anyways, I would go ahead and go with an Alltrax upgrade and save yourself some hassle down the road ;)

[stang99x]

I'm all for upgrading, but in my experience the Club Car Controllers have been very solid with very few issues or failures. I would say I've replaced 20 EZGO controllers to 1 Club Car IQ drive. I've been pondering trying one of the new controllers MadJax recently released with the user setting control box that mounts on the dash. They are expensive as all get out, though it might be beneficial for what you are using it for. You can see one at this link: /www.mymadjax.com/Shop-by-Category/Performance/Torque-600amp-Controller-powered-by-Navitas.html I've not used it, though I have heard good things about it. My Madjax rep has been trying to get me to do one for a couple weeks now.

[ClubCarCooter]

Thanks Stang...

I dug into my controller for a peek tonight and there is some 'partial' melting of the terminal block for the big gauge cables. The top one is clean and no melting. The middle and lower spots have run hot enough to partially melt the plastic body below the ring terminals. Even if my controller is not giving the trouble I have been having, it ain't good to have enough heat to melt things. A high resistance is happening somewhere.

[stang99x]

Originally Posted by ClubCarCooter

Thanks Stang...

I dug into my controller for a peek tonight and there is some 'partial' melting of the terminal block for the big gauge cables. The top one is clean and no melting. The middle and lower spots have run hot enough to partially melt the plastic body below the ring terminals. Even if my controller is not giving the trouble I have been having, it ain't good to have enough heat to melt things. A high resistance is happening somewhere.

Yes there is some resistance somewhere. What size battery cables do you have? COmmon upgrades are to 4gauge and 2 gauge for the big boys. You won''t likely melt a 2 gauge though. I have made hundreds, probably thousands of cables in my time and the biggest baddest most modded carts always use 2ga (and the extreme of the extremist use 1 ga) If the controller is shot yet, you could try cables first. YOu'll need cables later anyway so you won't lose anything.

[scottyb]

Quote ...chest pounding... End quote


I'b like to recommend base jump flying. I haven't tried it but I saw a video and heard some really good things about it. It's expensive as all get out but, it might be what you are looking for.

[Sergio]

The "high resistance" is at the spot where the heat is developing, replace at least those 3 cables (2 on [B+] and 1 on [M-]) and make sure the connections are tight.

[ClubCarCooter]

Originally Posted by Sergio

The "high resistance" is at the spot where the heat is developing, replace at least those 3 cables (2 on [B+] and 1 on [M-]) and make sure the connections are tight.

I'll agree with that... the connections felt tight but still, connections are a weak link... the best made connections on high current circuits will always be a potential trouble spot.

I will make up new cables and hope that improves things... it's surely called for and might just be the only thing going on.

Thanks!