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Old 05-24-2016, 07:19 AM   #1
yourflorida
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Default 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Everything was working fine, Wifey went to ride and fails to go.

Key on. Direction switch to FWD. Strong solenoid click, pack at 37.5v

Press accel, shudders BACKWARDS, moves very little.
Controller, solid green.

Off. Wait.
Switch key on.
Switch Direction to REV, solenoid click, 5 RED Flash on controller.
No go.
B+ cable hot?
Throttle does nothing - RED led x5

Off.

I have check many things, but I am a little weak on the motor tests, and I am worried about the B+ heating up. I tried to meter the S1 S2, off of controller, they appear shorted, but I know I am only looking for a tiny Ohm.

Any help would be great, I have lurked at this site forever and respect you guys.

Thanks.


----------------------
My stable:
'56 Westinghouse (like the washing machine)
'71 Cushman 3-wheel (electric)
'76 Cushman 4-wheel (my runner)
'86 Cushman 3-wheel (gas)
'?? Cushman 3-wheel (gas, parts)
'96 EZgo (Wifey's runner)
'92 EZgo
'86 EZgo
'?? Club Car
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Old 05-24-2016, 07:48 AM   #2
JohnnieB
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

An Alltrax DCX controller with early versions of software can erroneously flash an Open Field (5-Red blinks) error. See Note: on attached excerpt from Alltrax manual.

The field windings in a DCS motor ought to measure in the 3Ω to 10Ω range.
If you are getting a short between the F1 and F2 cables, check for worn through insulation were 10 Ga cables are routed around frame. (see picture below)

If the controller's output to the field windings was shorted, it may have taken out the field excitation part of the controller.
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File Type: jpg DCX Error Codes.jpg (232.5 KB, 0 views)
File Type: jpg Worn field wire insulation.jpg (593.6 KB, 0 views)
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Old 05-24-2016, 07:55 AM   #3
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

That is exactly where I was gonna go
But the shudder now that is peculiar. A shudder usually indicates a bad battery or a bad connection. (Low power supply) Low voltage would cause high amp draw which could account for B+ cable temp rising.
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Old 05-24-2016, 08:54 AM   #4
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Some speculating.

If the field excitation output from the controller got wiped out, the controller might see it as an open field and give 5-red flashes.

If the armature excitation part of the controller is still intact, it would be feeding a stalled motor, so the armature current would be whatever the controller's amp limit is and that could warm up all the high current cables. The B+ cable getting hotter than the rest means it has more resistance.

With high amps flowing through the armature, some current is going to be induced into the field windings because the controller's output is PWM rather than straight-line DC. That might create enough magnetic flux get the armature to twitch a bit, which might make the cart shudder.
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Old 05-24-2016, 09:08 AM   #5
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Curious to see what the outcome is
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Old 05-24-2016, 05:49 PM   #6
yourflorida
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Good reasoned replies.....

Is there a way for me to test the field excitation section of the controller?

I am not thinking the "bad connection/battery", still strong 37+ even when messing with it.

Thanks again and any tips on checking the field circuit would really be great.
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Old 05-24-2016, 05:57 PM   #7
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Just grabbed another meter, tested the Field to the motor...... SHORT.


Arrrghhhh.

Is there any "user serviceable parts" for the Field coil in the motor?

Anyone wanna sell a used DCS/36v motor?
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Old 05-24-2016, 06:14 PM   #8
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Here is how to test the motor.
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File Type: jpg Motor Test - Sepex.jpg (91.7 KB, 0 views)
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Old 05-25-2016, 01:10 PM   #9
yourflorida
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

Update...

Cleaned motor, inspected the S1/S2 cables.
Tested OHM again, and now I show a solid 2ohm....

Back to the starting point.

FWD - Green solid. Hit Accel and wheels run reverse (lifted now).
REV - 5 flash RED. Do not even have to hit the Accel

Help me understand the FIELD circuit: the controller provides juice to the coil (S1 - S2) to establish direction?

If that is the case, will the motor go wrong direction if S1/S2 are swapped?

Is there any value to attaching laptop and poking around in the controller software?

(I have an older '92 model with original controller/motor. Does that help any? )
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Old 05-25-2016, 01:27 PM   #10
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Default Re: 96 TXT DCS with Alltrax, no go. 5 Red in REVERSE (shudder backwards in FWD)

S1 and S2 in a Series motor are in Series with the A1, A2 (Armature) The field is a very low resistance. Usually a Sepex motor has the field labeled F1, F2. Which motor do you have?
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