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Old 10-23-2015, 11:16 PM   #11
scottyb
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Default Re: Need help with Speed Controller

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Originally Posted by cartattach View Post
No I'm not using a 400 at this point, I'm running a stock 1510. But as I see above, JohnnieB is using them on his 400.
Johnnies 400 is peaking at $60 amps and has sustained outputs equal to a DCX500. You can't compare ratings you need to compare output. AND johnnie has 2g cables because he bought them for his 500DCX.
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Old 10-23-2015, 11:31 PM   #12
Snowman2
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Default Re: Need help with Speed Controller

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Scottyb....I just looked a previous post of yours explaining the different carts and mine is a Series....it does not have a tow switch and the F/R is on the right in front of the controller

Sorry for the confusion....

Thank you for the responses.....I am going to install 2 gauge throughout the cart this week and see it the singing noise stops. Small steps to get to the problem. I just ran the cart at night with 4 people on it for 5 miles with several stop and goes and it did fine.....the temp of the 4 gauge cables was 110 to 130.....the speed controller was the same.....

Thank you again....
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Old 10-24-2015, 06:59 AM   #13
scottyb
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Default Re: Need help with Speed Controller

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Originally Posted by scottyb View Post
Johnnies 400 is peaking at $60 amps and has sustained outputs equal to a DCX500. You can't compare ratings you need to compare output. AND johnnie has 2g cables because he bought them for his 500DCX.
Peak is 460 not $60
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Old 10-24-2015, 09:48 AM   #14
JohnnieB
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Default Re: Need help with Speed Controller

Quote:
Originally Posted by cartattach View Post
No I'm not using a 400 at this point, I'm running a stock 1510. But as I see above, JohnnieB is using them on his 400.
Quote:
Originally Posted by scottyb View Post
Johnnies 400 is peaking at 460 amps and has sustained outputs equal to a DCX500. You can't compare ratings you need to compare output. AND johnnie has 2g cables because he bought them for his 500DCX.
Actually, 2Ga silver soldered cables was my first upgrade and I installed them of a completely stock PDS cart because I firmly believe overkill is underrated.

The cart was only 3 year old when I got it and the OEM cables were not visibly corroded and appeared to be in like new condition physically, but having worked with electrical and electronic gadgets for 50+ years, I detest crimped on connectors and proactively replaced them. I'm also a bit OCD about efficiency and 2Ga passes amps 59% more efficiently than 4Ga, so I went with 2Ga, which would also allow me to go up to 500A with acceptable (to me) cable losses.

FWIW: I had access to a milli-ohmmeter with 4-wire test leads. so I measured the 2Ga cables before I installed them and measured the OEM cables they replaced. Like I mentioned , the OEM cables were only 3 years old and looked good to a critical eye, but the all had several milliohms of resistance while only the longest of the 2Ga silver soldered cables registered anything of the milli-ohmmeter. The display only resolved down to 0.001Ω, but the least significant digit was flickering back and forth between 0 and 1, so the resistance of the longest of the 2Ga cables was roughly 0.0005Ω, which is the nominal resistance for 3 feet of AWG 2Ga copper.

Needless to say, my cables barely get warm even when my motor climbs above 200°F and my controller approaches 120°F.


Ironically, Alltrax appears to have revised their cable size recommendations.
Attached is a snapshot of the lower right area of their XCT in a PDS wiring diagram.

Personally, I wouldn't put 6Ga cables on anything bigger than a mobility scooter, but like I said, I'm an efficiency nut.
Attached Images
File Type: jpg Alltrax Cable recomendations..jpg (126.4 KB, 0 views)
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Old 10-24-2015, 10:54 AM   #15
Klunky Chris
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Default Re: Need help with Speed Controller

It could be time to clean all your connections? Maybe you have a less than optimal resistance on some or all of your cable lugs? How is your battery pack voltage measured at the pack when the problem arises?

New cables are probably in order, but it doesn't cost anything to clean all your connections for a test.
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Old 10-24-2015, 09:46 PM   #16
Snowman2
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Default Re: Need help with Speed Controller

Thank you for all the help. Just ordered new cables (2gauge). Going to install and see how that helps. I'm sure it's going to be a big difference
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