Faulty Sevcon controller

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Ribfeast
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Joined: Thu, 07 Feb 2019, 12:15

Faulty Sevcon controller

Post by Ribfeast » Wed, 01 May 2019, 06:26

My girlfriend parked up the Toro Workman MDE 48V kart yesterday and then went to use it later in the afternoon, it makes all the right noises (reverse beep etc) but the main contactor doesn't click on, and getting 4 flashes on the dash.
Tried bridging the 2 large terminals on the contactor to allow current flow but this didn't make a difference.
Applied 48V to the contactor and it clicked over fine and reads 0 ohms when energized, so it appears OK. So it seems the Sevcon isn't outputting a contactor charge to energize it. It's now just giving 3 flashes which indicates the controller is likely faulty :(

So it appears that I have a faulty Sevcon Millipak controller. Does anyone know where I can get one of these affordably? Most seem to be around $700-1000US :(
It's a model 633T46301.
Are some of the other visually similar models interchangeable? eg: https://www.cartpartsrus.com/SevCon/sevcon.htm
I think these work by switching things to ground, vs switching to positive, so not sure if I can change to another brand of controller.

If I was to buy a new Sevcon, would it need to be programmed also? Or just plug and pray?
Does anyone maybe have a good one they are selling?

I've pulled it apart and it's full of that black potting epoxy, so I'm going to have a hard time getting to the innards to try and repair it otherwise. Has anyone repaired one successfully? Any tips on getting the epoxy out safely?

Thanks for any help :)

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