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Old 06-18-2020, 01:09 PM   #1
Ez mobility
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Unhappy Motor overheating

Long story short: 1997 EZGo DCS with tow switch. Motor getting so hot u can't touch. Replaced batteries, # 2 gauge wires, solenoid and the controller rebuilt. Controller got hot and melted part of top cover and solenoid melted side post and wire from solenoid to controller. Still after checking all components for correct voltage readings it still gets so hot within 2 minutes it stops. After it cools it will :lhmo. go for only about 1 minute. Checked motor ohms for shorts and checked armature for all readings. NOW I know what some r thinking🤔.
So I have another EZ Go so I swapped batteries And motor into this 1995 and it works great, runs and runs and no overheating so? Solenoid resistor voltage testing is correct ( drops 3-4 volts on controller side) and ITS voltages correct So what is going on with this cart?
Another thing: motor appears to be shunt but has A1 A2 and S1 S2. All cables were right and checked with ohms meter. One more thing: No large wheels or other mods. About the only thing to replace on 97 is: ITS and resistor.🤔
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Old 06-18-2020, 02:26 PM   #2
JohnnieB
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Default Re: Motor overheating

The easy one first. The DCS sepex motor studs were labeled A1 & A2 and S1 & S2 the same as a series motor and the only ways to tell them from a series motor are the model number or pulling the motor and looking at the field windings. Series motors will have a few turns of thick wire or ribbon type wire (attachments 1 & 2) while a sepex motor will have several turns of thin wire (Attachments 3 & 4 - DCS and PDS respectfully)

The labeling was changed when the DCS was replaced by the PDS, probably because series and sepex motors were getting mixed up and controllers taken out as a result.

--------------

If I read your post correctly, the motor and batteries run fine in the 95 DCS but the motor and controller overheat in the 97 DCS. Does that mean nether the controller, solenoid nor cables were swapped?

The first thing I'd check is for a mechanical drag of some kind. Brakes dragging, bad bearings, oil in differential turned into glue, etc.

Does the 97 push as easy as the 95?
Attached Images
File Type: jpg Series Motor.jpg (662.8 KB, 0 views)
File Type: jpg AMD 7126 Raptor.jpg (317.9 KB, 0 views)
File Type: jpg ezgo-dcs-motor-2.jpg (38.7 KB, 0 views)
File Type: jpg Stock PDS Motor.jpg (38.1 KB, 0 views)
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Old 06-18-2020, 10:05 PM   #3
Ez mobility
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Default Re: Motor overheating

Ok first. It's a series motor. No drag, rolls very easy, fresh trans fluid. The 97 is a DCS, the 95 isn't. 97 has 9 pin controller and 95 has 5 (I think without going back out to check.) The 9 or 11 pin controller was rebuilt. Strange that new number 2 wire and batteries on 97 didn't help. The 95 has original well worn wires and oe controller and motor and batts. work great when installed on 95 none DCS. Like I said only 3 things left to change on 97,but resistor, ITC and wiring. Checked all these with extreme care. ITS checks correctly and resistor drops 4 volts on controller side. Invested too much in 97 to give up now! Also this is second time controller has fried so?
Will series motor work from a 94 none DCS to DCS and 97 controller? Just discovered this series motor isn't what came on 97. Motor was swapped from another 94 or 96. But it had been on there for many years without any issues until now.
Has anyone had this issue? Help.
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Old 06-19-2020, 09:27 AM   #4
JohnnieB
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Default Re: Motor overheating

Series and sepex motors and controllers are not interchangeable. Connect a series motor to a sepex controller or a sepex motor to a series controller and bad things are going to happen.

As for the 97 DCS cart. The stock DCS controller (Curtis 1206SX) was a failed design that lacked under-voltage protection, so it failed often and was replaced by the PDS drive system after only 5 years, or so, of production.

Alltrax made a plug-n-play replacement for the 1206SX that corrected the design flaws. It was called the DCX, but is no longer in production either. It has been replaced with the XCT48x00-DCS family of controllers.

If you like the 97 DCS, put a XCT48400-DCS in it. Make sure the field map installed matches the motor that it will be connected to.
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Old 06-22-2020, 11:07 AM   #5
Ez mobility
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Default Re: Motor overheating

Explain to me how controller controls amps to DCS motor is different than to a series motor.
Thanks
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Old 06-22-2020, 01:52 PM   #6
JohnnieB
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Default Re: Motor overheating

Quote:
Originally Posted by Ez mobility View Post
Explain to me how controller controls amps to DCS motor is different than to a series motor.
Thanks
In a series drive, exactly the same amps that flow through the armature also flow through the stationary windings (aka Stator or aka Field). The speed control valve is a bunch of MOSFETs in parallel capable of passing several hundred amps of current to the motor. There is a single speed control valve in a series drive controller.

In a sepex drive (DCS, PDS, TXT48, etc.) the amps flowing through the armature are different than the amps flowing through the stationary windings. The word Sepex is a contraction of the phrase Separately Excited and means the armature and field are fed (excited) by separate sources. A sepex drive controller has two control valves made up of MOSFETs in parallel. A high power one that passes several hundred amps to the armature and a low power one that passes up to about 50A to the stationary windings.

----------
The speed/torque curve of a series motor is cast in stone at the factory, but the speed/torque curve of a sepex motor can be altered during operation by altering the number of amps the stationary windings are allowed to draw.


Bottom line is that mixing series and sepex motors and controllers is a no-no.
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Old 06-22-2020, 02:29 PM   #7
Ez mobility
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Default Re: Motor overheating

Ok. Great explanation. Now, what would happen to a series motor connected to sepex controller and vise versa?
Thanks for all info.
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Old 06-22-2020, 04:00 PM   #8
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Default Re: Motor overheating

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Originally Posted by Ez mobility View Post
Ok. Great explanation. Now, what would happen to a series motor connected to sepex controller and vise versa?
Thanks for all info.
Series motor and sepex controller: The stator windings of a series motor will draw more amps than the field windings of a sepex motor for the same applied voltage and may burn out the low power set of MOSFETs in the sepex controller.

Sepex motor with a series controller: The armature of the series motor will draw more amps through the thin wires of a sepex motor field winding and may burn them out.

In either case, the cart's peforemance will be lousy as long as the motor or controller lasts, which may not be very long.
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Old 06-23-2020, 06:57 AM   #9
Ez mobility
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Default Re: Motor overheating

Ok. Thanks a bunch. So glad we found someone that could give an understandable answer!
You wouldn’t believe how much wrong advise we have received!☹️
I retired from auto service so we never got into sepex or series motors. Of course now with electric vehicles, technicians will Need more training.
Hopefully you will keep posting and helping us learn more.
Thanks again
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Old 06-23-2020, 07:01 AM   #10
Ez mobility
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Default Re: Motor overheating

Oops, one last? What do u think about using lithium batteries in carts? I found some good used that doesn't cost too much more than the lead acids. Thanks
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