98 EZGO Alltrax/Solenoid/SW202 Upgrade - Wiring not working

[Dmoney]

In forward it would go green - green - then red six times
checked in reverse and the tires started spinning in reverse - just green light when pedal was pushed

then check forward and tires were spinning with green light on

Wow - dont know what i did

[Dmoney]

I did not hold it wide open to get to yellow - was still worried about the wiring.
I think i need to hook up my computer and see what it says with the two green and red flashing leds

[Dmoney]

tested it on the computer and everything seems to be working - no errors from the alltrax software. no more red lights flashing

[JohnnieB]

The 2-green 6-red flashes is the "Low Throttle Under Range" error code.

The throttle voltage on an Alltrax controller is measured between the black and the white wires.

Pedal up (High Throttle) is 10.0V and pedal down (Low Throttle) is 6.0V, so the error is saying the pedal down voltage is less than 6.0V.

In post#9 you state there is 5.7V on the the white wire (with black test lead on B- ????) and 1.5V on the black wire, which means there is only 4.2V between the black and white wires when there should be 6.0V.

There must be some tolerance on those voltages, but I don't know what it is.

[Dmoney]

Ok, I was busy for the last 10 days and just got back to the cart. The cart was running 9 says ago on the jack stands - forward and reverse.
Yesterday, I took it down and tried to go aroud the block and forward stopped working. reversed back to garage and then reverse stopped as well. Turned everything off and let it sit until today and I put it back on jack stands and now only reverse is working

I put my DVM on the white and black wires. Here are my results.

from battery negative- to white wire (J4) on controller
pedal up------|-----solenoid click------|-----full pedal down
.65mv------|-----7.7v------|-----5.8v

from battery negative- to black wire (J5) on controller
pedal up------|-----solenoid click------|-----full pedal down
0.00------|-----.9v------|-----1.46v

DVM between white (J4) and black (J5)
pedal up------|-----solenoid click------|-----full pedal down
6.4 mv------|-----6.1v------|-----4.3v


I now have a different set of things happening.
The cart is jacked up and wheels turn freely.

In Reverse - MZJ 400 soleniod clicks, SW202 clicks, the wheels spin.
In Forward - MZJ 400 soleniod clicks, SW202 clicks, the wheels DO NOT spin.

With computer hooked up and Alltrax software log monitoring going.
In forward I see Shutdown and Overcurrent immediately.
In the log file on forward - I see Global Shutdown, HPD Ran, and Overcurrent flags

In the log file on reverse - I see just HPD Ran, and Overcurrent flags.

????
One other thing I noticed is on the computer software on the left- it says under Controller Info - Voltage Rating = 48V , I have a 36V battery pack

There are no led error lights on controller thoughout all these tests.
On pedal pressed to solenoid click - blinks 4 times green
On pedal press - turns solid green the goes to yellow at full pedal down.
It does this in all three positions - Forward, Reverse, and Neutral

I added my last log file as well.

Thanks for your time and help. I am just hoping to get this sorted out

[JohnnieB]

1. Easy one first. The 48V rating only means that the SR controller is capable of running with a battery packs up to 48V.

2. A series drive running in one direction, but not the other means there is an issue in the F/R switch, or the reversing contactor.

It was working in both direction , then neither direction and now only reverse, so I suspect there is a pieces of debris floating around and getting between the contacts, or something is binding the mechanics of the solenoids.

3. The ITS voltage for all Alltrax controllers is measure between the black and white wires.

Should be 10V when solenoid clicks and 6V when pedal is on floor.
You have 6.1V and 4.3V, which probably should be triggering the "Lo_HThrot_Overange" and "Lo_LThrot_Overange" error flags, but isn't.

4. Two things about the data log.

a. Use the continuous sample rate. The 1 second sampling rate is too slow to see much of anything useful.

b. Zip and attach the raw ".csv" file rather than importing it into EXCEL and zipping the ".xlsx" file. (You mentioned an overcurrent flag in reverse, but there isn't one in the .xlsx file posted, so has the EXCEL file been edited or were you speaking about a data file that wasn't posted?)

[Dmoney]

Here is the log file. I set it to continuous. I hit the pedal in forward two times and then in reverse two times.

[JohnnieB]

The throttle is going to 100%, so it appears the SR's auto cal function is compensating for the weird ITS voltages.

The battery voltage that is being applied to the controller is being outputted like it should be, but no amps, so there is an open someplace in the high current circuit (Stuff connected by heavy cables).

Since it works in Reverse, the only difference is in the reversing contactor.
My guess is the contacts in the solenoid used for Forward are not making contact for some reason. Either the coil isn't being energized or the contacts are blocked.

[Sergio]

Well, I just noticed the comment he mentioned was mine and it is my fault here.

My description of what needed to be changed is correct, the Controller B+ should be connected to the top bus-bar that spans the two top posts, good practice even if the Reversing Contactor does not have a big + indicating magnetic blowouts have been installed.

Unfortunately, I did a typo error on which Motor post was connected there.

The existing drawing shows A2 connected to that bus-bar.

The correct exchange should have been to swap A2 with the Controller B+ connections at the Reversing Contactor.

As it is now the cart cannot run if Forward.

[Dmoney]

I swapped the two wires and swapped the forward reverse wires to match the original mockup - I now have wheels going forward with forward switched on. I switch to reverse and get no wheels spin.
I have attached the mock-up picture showing what I am currently set up as.
I also attached the SW202 switch picture.

My SW202 is a bit different than the one in the mock-up picture - the bottom bolt that goes to motor A2 is on the left side.

I feel that we are very close to victory!

Thank You again for your time and advice!