Bad solenoid

[brownleaf]

Running 97 dcs ezgo, 48v, alltrax 400, 4 ga wires and 48v white solenoid. Also regular tires.I`ve been running this setup for 8-9 years. Is it normal to burn up a solenoid every 3-4 years with this setup? Also running the 470 ohm resistor and 3a diode on solenoid.

[JohnnieB]

When you say "burn up a solenoid", are referring to the solenoid's coil or the solenoid's contacts?

The solenoid coil should last forever, unless the voltage is too high.
You say it is a 48V solenoid and it is in a 48V system, so the solenoid coil shouldn't be causing any problems.

Solenoid contacts eventually fail. The higher the amp rating the longer they will last.
With a 400A controller, you need a 200A solenoid or greater.
If the Amp rating of the solenoid(s) you've been using is less than that, that is likely to be the reason they are failing.

The resistor connected across the solenoid's larger terminals reduces arcing when the contacts close, and prolongs contact life.
470 Ohms, is the correct value for a 48V system.

For maximum solenoid contact lifespan, get the 48V Super-Duty solenoid (400A continuous/1000A peak) shown near the bottom of this webpage:
http://www.cartsunlimited.net/Custom_Options.html

[brownleaf]

Thanks Johnnie.....Its a white Rodgers 586 200a, had to replace it. Third one in 8-9 years. Looks like 400a is the way to go..Thanks

[yurtle]

Tear it open and report back what you see. I melted two stock solenoids with stock motor, controller, and tires. The internal contacts overheated, so it still clicked, but became unreliable, as some of the plastic covered part of the contact stud, which caused it ho heat up even more. I god a HD solenoid from ScottyB and never had a problem again.