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Old 06-17-2019, 09:18 PM   #21
NoleFan4Ever
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Default Re: 2010 CC DS throwing main drop out fault

Quote:
Originally Posted by twilliams81 View Post
-snip- Weird crazy stuff
I agree.....
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Old 06-17-2019, 09:27 PM   #22
twilliams81
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Default Re: 2010 CC DS throwing main drop out fault

Can you explain what the main drop out harness is? And why did they stop making them?


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Old 06-17-2019, 11:10 PM   #23
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Default Re: 2010 CC DS throwing main drop out fault

Some of the earlier IQ harnesses did not contain some resistors and this would cause a fault and cause it to "drop-out". That was corrected in the latter harness so I am not sure why they quit making it. I asked David Hicks and he had no idea why.....

I think Sergio or someone here had looked into it before and determined what type resistors were in the drop-out harness. I installed several, but never looking into them further.
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Old 06-18-2019, 05:47 AM   #24
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Default Re: 2010 CC DS throwing main drop out fault

The main dropout was a $20+ solution for a $0.30 problem.

As we discussed earlier the issue was a software bug in the early IQ carts that caused the Controller to generate a "main dropout error" during some Regen to motoring transitions.

Club Car then developed the Excel system which was superior in Regen capability, did not have that issue and it was a safer design by having those harness resistors that allow the Controller to identify a short that could potentially cause a runaway condition.

Club car eventually got a version of the IQ Controller (circa 2009) that had those diodes built-in, but it has since discontinued the older IQ anyway.

The $0.30 diode I linked is better than the one on the old overpriced dropout harness anyway and it is not that difficult to install.

This is the first time you mentioned an "open armature" error.

Since you already replaced the Controller, if the A1 and A2 cables are in good shape, the Motor (typically the brushes) is the only other cause of the "Open Armature" error.
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Old 06-18-2019, 12:31 PM   #25
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Default Re: 2010 CC DS throwing main drop out fault

Back again and I wouldn’t believe it if I didn’t see it for myself but I took the motor off of a working cart and put it only to have the EXACT same thing happen. Open armature/main coil faults and cart shutting down after only a few feet. Just out of curiosity...would an alltrax controller require the same inputs as this IQ setup? Would that be an alternative if I can’t get this problem worked out? I’m at my wits end


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Old 06-18-2019, 12:37 PM   #26
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Default Re: 2010 CC DS throwing main drop out fault

That is whacked! The Alltrax has a similar Alarm code for the Field, but I do not know about the Armature:

1-GRN (+) 1-RED LED flash = Over Current/Short Circuit
1-GRN (+) 2-RED LED flash = Battery Under Voltage
1-GRN (+) 3-RED LED flash = Battery Over Voltage
1-GRN (+) 4-RED LED flash = Over Temp (Check connections)
1-GRN (+) 5-RED LED flash = Motor Field OPEN alarm (Check connections)
1-GRN (+) 6-RED LED flash = Pre-Charge Failure
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Old 06-18-2019, 12:39 PM   #27
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Default Re: 2010 CC DS throwing main drop out fault

I do not see where David has weighed in, but if Sergio does not have another idea, I would call David Hicks at Revolution Golf Cars 706-431-3917 and ask him if this has came up with him before.....

It has to be something someone else has already gone through and I know he seen a lot while running the shop for CC.
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Old 06-18-2019, 12:40 PM   #28
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Default Re: 2010 CC DS throwing main drop out fault

10-4 I’ll give him a ring


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Old 06-18-2019, 04:28 PM   #29
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Default Re: 2010 CC DS throwing main drop out fault

After further evaluation and talking with David it’s possible that the input shaft may be bent/warped and causing the armature to make contact with the field coils...I took the original motor off the cart and put it on another cart and it runs perfect. Would anyone be able to tell if this input shaft does indeed have a bend to it from looking at a video? Not sure how I can post it but I do have one




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Old 06-18-2019, 06:23 PM   #30
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Default Re: 2010 CC DS throwing main drop out fault

What about new cables from the motor to controller?
If the input shaft is bent that bad I think it would be obvious.
One wheel off the ground, other wheel on, spin the raised wheel and watch the input shaft. It would wobble all over the place if it's bent bad enough to run the motor armature off center. You would also have one hell of a vibration.
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