Wire from solenoid to controller appears to be melting, what could be the cause?

[Jeffreynmandy]

I don't know when it happened, I've put about 25 miles on this build. The jacket looks like it's melted and a little brittle.

Should I go with a bigger wire, or is it because I'm temporarily running a 36v solenoid on a 48v build? I know, I'm changing it soon.

[Volt_Ampere]

Something is wrong. That wire should not be carrying enough current to get hot and melt.

[Jeffreynmandy]

Originally Posted by Volt_Ampere

Something is wrong. That wire should not be carrying enough current to get hot and melt.

I just noticed it tonight, but I took that picture right after I got the cart back, so I've drove it at least 10-15 miles since. I'll replace it and see if it does it again. I doubt it was like that when installed.


It runs fantastic. It'll hit 30mph, I don't know what it could be.

[DaveTM]

Hmmmmm......I would give Alltrax a call and ask their opinion. It couldn't hurt.

[JohnnieB]

[QUOTE=Jeffreynmandy;1201617]I don't know when it happened, I've put about 25 miles on this build. The jacket looks like it's melted and a little brittle.

Should I go with a bigger wire, or is it because I'm temporarily running a 36v solenoid on a 48v build? I know, I'm changing it soon.
Feeding 48V to a 36V solenoid is going to pump a lot of amps through that wire and most likely the reason it is overheating. Quite frankly, I'm a bit surprised the solenoid coil hasn't burned out.

Installing a 48V solenoid is the best solution.

If you insist on using the 36V solenoid a bit longer, measure the solenoid coil's (All wire and diodes removed) ohmic value and insert a 5W resistor with about 1/3 of that ohmic value in series with the black wire.

[cgtech]

If you do that, be sure to use a resistor rated at 1 watt. Might be harder to find, but when it doesnt burn out on you in the middle of nowhere, you will be glad you did.

[Jeffreynmandy]

Thanks for the replies, I'm going to move up replacing the solenoid and f/r. I'm pulling the body off soon for paint, I'll try to get the solenoid and f/r done while it's off.

[scottyb]

Another thing is make all the high amp cables the same size. I see 6 - 2g This is what we call a halfast install

[Jeffreynmandy]

Originally Posted by scottyb

Another thing is make all the high amp cables the same size. I see 6 - 2g This is what we call a halfast install

It's partly my fault, I bought all the stuff used and told him I was on a budget. He took it literal. I would have payed for the solenoid.

He rewired the entire cart, cut and made new ends on all the cable I had, installed the motor, controller, cables, batteries, and had to troubleshoot down a pinched wire.

It was as nightmare because everything was untested. He didnt know if the parts were bad or what when it didn't work right. The wire was pinched under the cart going to the ITS.

He did all that for $1000 including the new T-875 Trojans.