So I started this thread but it kind of ran out, and I haven't solved my issue. I have a 1993 Club Car DS with following upgrades:
48V
FSIP 700 amp controller
400 amp solenoid
potentiometer
Heavy duty F&R switch
4" lift
23" tires
Battery pack is fully charged.
A week or so ago, I go to unplug the DPI charger, and use it, and solenoid will not click. I discover that the positive side of the solenoid is missing. I trace it to the potentiometer, which is not putting power out of the micro switch to the positive side of the solenoid.
I then remove the potentiometer. It has a fried micro switch and something that looks like this on the pot itself:
http://www.buggiesgonewild.com/attac...m-img_3619.jpg
I test the pot output and it gives from 0-5,280 Ohms. I then replace the microswitch. and reconnect the pot. I turn the key on and press accelerator. Wire from F&R switch to pot "jumps" as in moves like it becomes energized, but no clicking from solenoid. Then, I notice the micro switch on the pot is fried again. A small puff of smoke comes from the area of the solenoid. Don't know what side.
I don't know if just turning the key on fried the potentiometer micro switch or if pressing the accelerator did. Seems to me it was just turning it on, but who knows. I have tested the continuity of the F&R microswitch when cart is off, and it checks out. I have not checked the key switch, but it seems OK because it is giving my mounted digital voltmeter the right voltage. I have also checked the two small contacts on the solenoid with everything removed from solenoid. It was fine.
It seems that something has a short somewhere. I am hoping it isn't the controller.
I'm afraid to do anything else at this point because I don't want to burn anything up. I have checked the wiring, and it is wired correctly. It's wired the same way it's been wired for a few years after the conversion, so I am guessing it's not that.
Sorry for the long post, but if you have any thoughts, please let me know.
48V
FSIP 700 amp controller
400 amp solenoid
potentiometer
Heavy duty F&R switch
4" lift
23" tires
Battery pack is fully charged.
A week or so ago, I go to unplug the DPI charger, and use it, and solenoid will not click. I discover that the positive side of the solenoid is missing. I trace it to the potentiometer, which is not putting power out of the micro switch to the positive side of the solenoid.
I then remove the potentiometer. It has a fried micro switch and something that looks like this on the pot itself:
http://www.buggiesgonewild.com/attac...m-img_3619.jpg
I test the pot output and it gives from 0-5,280 Ohms. I then replace the microswitch. and reconnect the pot. I turn the key on and press accelerator. Wire from F&R switch to pot "jumps" as in moves like it becomes energized, but no clicking from solenoid. Then, I notice the micro switch on the pot is fried again. A small puff of smoke comes from the area of the solenoid. Don't know what side.
I don't know if just turning the key on fried the potentiometer micro switch or if pressing the accelerator did. Seems to me it was just turning it on, but who knows. I have tested the continuity of the F&R microswitch when cart is off, and it checks out. I have not checked the key switch, but it seems OK because it is giving my mounted digital voltmeter the right voltage. I have also checked the two small contacts on the solenoid with everything removed from solenoid. It was fine.
It seems that something has a short somewhere. I am hoping it isn't the controller.
I'm afraid to do anything else at this point because I don't want to burn anything up. I have checked the wiring, and it is wired correctly. It's wired the same way it's been wired for a few years after the conversion, so I am guessing it's not that.
Sorry for the long post, but if you have any thoughts, please let me know.