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Fried Controller

08/14/2012 8:12 AM

A friend recently brought me a controller from a golf cart,asking me to take a look.No hurry, since he had already replaced it.

When I finally got around to opening it uo, I was surprised to see the most catastrophic failure of a board that I have seen in a long time.

10 Mosfets,with associated circuits, were totally smoked,and barely recognizable.

They were all massively heat sinked, but heat damage was confined to the cases of the Mosfets primarily.The only salvageable parts were the aluminum heat sinks.

As a general rule, Mosfets are load sharing, so I suspect an input polarity reversal did this damage.(But user denies this ).

Anyone else have a similar problem in their memory banks?

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#1

Re: Fried Controller

08/14/2012 9:44 AM

Not seen anything like that, but my guess would be, if it wasn't reversed, maybe it was stalled. Perhaps accidentally switched on whilst parked up against a wall or some such. Sounds like the circuit could have done with some protection.
Of course the other possibility, being on a golf course would be lightning strike.
Big bolt comes down, misses the one iron and hits the controller (like the old joke says, even big G can't hit a one iron!)
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#2

Re: Fried Controller

08/14/2012 10:00 AM

I vote for an indirect lightning strike on this one.

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#3

Re: Fried Controller

08/14/2012 10:03 AM

Just a wild guess but I can only think of one scenario that would toast all transistors simultaneously. The DC motor generated a sufficiently large back EMF that toasted all of the MOSFETs in one shot. A downhill rolling overloaded cart trying to stop with dynamic braking might generate the correct conditions for this scenario.

A more likely scenario would be a very fast progressive failure and not a simultaneous execution of silicon. A MOSFET or two stopped conducting for any one of a number of reasons. (Most of the failure reasons will be heat related so the transistors in the middle of the heat sink would be suspect.) The cart was still usable but the remaining transistors were now slightly exceeding their preferred current handling. This higher current in the remaining transistors raised their heat production. With one transistor after another removing themselves from the current share there eventually was a load condition that exceeded all of the remaining transistors at once. Pop goes the MOSFET. Finally a technician sees this aftermath and all of the transistors resemble charcoal.

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#5
In reply to #3

Re: Fried Controller

08/14/2012 11:30 AM

Interesting thought, but I generally find FETs failing short circuit.
Although maybe that's just Murphy's law as a short circuit is the worst condition in the chemical dosing field.
60L of starch dumped into a laundry machine isn't funny... well ok, it is funny, just rather embarasing.
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#4

Re: Fried Controller

08/14/2012 11:11 AM

This could be the from the board making contact with the motor due to hitting bump while heavily loaded....This has been reported on some models....The fix was silicone globbed on top of terminals...or it could be from age, just wearing out as somebody mentioned...or it could be due to overheating from driving slow for long periods of time, or uphill, or towing, or unknown variable...

http://www.buggiesgonewild.com/

http://server1.buggiesunlimited.com/phpBB2/index.php

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#6

Re: Fried Controller

08/14/2012 12:03 PM
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#7

Re: Fried Controller

08/14/2012 12:30 PM

Its a rather common issue with high current circuits that have multiple devices sharing the load.

One or more loose connection either externally due to a bad solder connection or corroded terminal or one simply just fails internally to a open circuit or short circuit.

If enough devices go open circuit for any number of reasons the remaining ones get a current overload and blow up in a firey death. Or if one goes dead short it tries to take so much current it literally melts down its internal connections creating a often times violent internal arc which when coupled with having a large inductive load such as a motor in series with it easily creates uncontrollable high voltage spikes and surges which in short order wipe out any remaining devices in a similar fashion until either the system has burnt itself to a crisp or a fuse or breaker blows.

When I have to design a power handling circuit for high current applications I always try to use one large switching device, or at most two devices built into a single component unit, opposed to many smaller and cheaper devices.

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#8

Re: Fried Controller

08/14/2012 2:36 PM

Further questioning of my friend revealed that he had also had to replace the motor,and used it for a core.

I went to the shop where he had the work performed,and they still had the motor.It was disassembled,and I could see the armature.It was obviously the source of the problem.

The commutator segments were "smeared" together,with barely a gap between most segments.I do not see how it ran long enough to get to that point.The "off brand" controller must be tougher than I thought,having endured severe overload and counter-EMF for a long time before finally giving up.

The repair shop said that there was no core value for the board, or any board of that brand.I can see why.A repair would be very labor intensive and expensive.

Mystery solved...I think..

Thanks for everyone's input on this!

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#9
In reply to #8

Re: Fried Controller

08/15/2012 10:59 AM

Thanks Hitekredneck for the update. It's nice that guys keep others informed as to the outcome of a problem.

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