New D&D Torque Motor (4:1) - Not Seeing 40% Torque

[JeffJulian]

Here is the log from the controller for Throttle Position (%), Battery (Volts), Current Output (Amps), and Battery Current (Amps)

GOING THROUGH THE YARD

ThrottlePos BatteryVoltage OutputCurrent BatteryCurrent
12 37.6 40.0 4.9
24 36.3 108.0 25.4
24 36.3 116.0 27.3
22 36.4 104.0 23.2
20 36.4 116.0 23.2
20 36.4 124.0 24.3
20 36.4 128.0 26.1
21 36.3 120.0 25.4
21 36.3 108.0 22.9
22 36.3 112.0 24.6
31 35.7 152.0 47.7
56 35.1 137.0 76.8
87 34.7 156.0 136.4


FLAT ROAD AND DOWN AND UP HILLS, 100% THROTTLE

ThrottlePos BatteryVoltage OutputCurrent BatteryCurrent
100 34.9 100.0 100.0
100 35.4 64.0 64.0
100 35.6 56.0 56.0
100 35.8 44.0 44.0
100 35.9 40.0 40.0
100 36.1 32.0 32.0
100 36.2 28.0 28.0
100 36.2 24.0 24.0
100 36.2 20.0 20.0
100 36.4 20.0 20.0
100 36.4 20.0 20.0
100 36.3 21.0 21.0
100 36.3 24.0 24.0
100 36.3 32.0 32.0
100 36.1 36.0 36.0
100 35.9 48.0 48.0
100 35.7 52.0 52.0
100 35.6 60.0 60.0
100 35.3 76.0 76.0
100 35.0 92.0 92.0
100 34.7 108.0 108.0
100 34.5 120.0 120.0
100 34.5 128.0 128.0
100 34.3 132.0 132.0
100 34.5 132.0 132.0
100 34.2 136.0 136.0
100 34.4 136.0 136.0
93 34.2 128.0 119.0
92 34.4 128.0 118.0
85 34.7 124.0 105.0

[JeffJulian]

Any one else got any ideas on why I am only seeing 120-150 amps on straight aways and 20-60 amps while climbing a hill with a 400 amp controller and D&D motor?

I have been searching all day for a hint of an answer to what could be causing this with no luck. Something is getting between the batteries and the controller to only allow it to produce/use 20-150 amps, but I dont have a clue what it could be.

[rabbitreborn]

Originally Posted by JeffJulian

I put in an AllTrax 400amp controller (AXE4845) and I am still not seeing any improvements up hills. At 400 amps, do I need to replace the Solenoid and if so, why?

Noone ever answered this so I will.....

Yes, you need to replace the solenoid and the reason is that the stock solenoid is rated for 70 AMPS. Replacing the stock unit with a 200-400 AMP unit will allow greater power flow through the solenoid.

This COULD actually be the bottleneck of the system at this point. Quite honestly, I am at a loss as to the exact cause of the problem. The ONLY other possible issue I can think of would be a badly wound motor (I'm really not a fan of D&D motors because of all the problems I have run into with them in the past such as bad windings, bad bearings, burnt armatures.....)

[JeffJulian]

My wife is on her way to pick up a White Rogers #586 from a local vendor. When I called her to pick up the diode and resistor, she said, "Are you sure you know what your doing?" I should have replied, "No, I got nothing here." Instead I said, "Yeah I know what I am doing, I hasn't blown up yet has it." :D Let's hope this is the problem!

[scottyb]

Have you upgraded the F&R switch? That is another potential bottleneck ....

[JeffJulian]

Originally Posted by scottyb

Have you upgraded the F&R switch? That is another potential bottleneck ....

No, but from what I gather, if it is not the Solenoid, then the only two components between me and the battery is the ITS Throttle and the F&R switch. I checked all the wiring to ensure it was tight, no problems there. Besides direction, what else does the F&R switch do in the processes?

[JeffJulian]

Absolutely no difference with the new White Rogers #586 Solenoid, :(

I am at a lost for words, what on earth is going on. I will run another round of diagnostics this afternoon/evening to see if the amps have changed getting to and through the controller.

I feel I have wasted so much money on this thing and I am getting the same performance I did when I started. Everyone talks about how these thing rip around with the upgrades I have done, but I don't see it.

[DOOmsman]

I am not a sparkler man, however the statement
I replaced the batteries 1 year ago is 1/2 the
information. What kind and size are the batteries?
That low amp flow may be all that they have.

[JeffJulian]

Originally Posted by DOOmsman

I am not a sparkler man, however the statement
I replaced the batteries 1 year ago is 1/2 the
information. What kind and size are the batteries?
That low amp flow may be all that they have.

The batteries are Crown Batteries, CR-200s and when I bought the cart they said they were replaced this past spring. Does anyone know where the manufacturing date is on these batteries?

[DOOmsman]

They seem to be a little smaller than a trojan 105

http://www.crownbattery.com/PDF/Crow...0Batteries.pdf