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Unread 06-12-2015, 08:48 AM   #1
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Default Changing 4 twelve volt batteries for 6 eight 6 volt batteries

We are working on a CC with four 12 Volt batteries and the charger gets quite warm on the backside of it (125 degrees ) Is this because the four , 12V config. or is it going to be a problem. Do we wait till the 12's are bad , are we going to lose the charger, how much heat can the charger bare? I know some Electronics are tested at 140 degrees not sure about charger.
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Unread 06-12-2015, 10:03 AM   #2
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Smile Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

The diodes that "rectify" the A/C power to D/C power are located in the back half of the charger and getting that warm is normal as long as the charger is actually getting the batteries charged up to the correct voltage. Most golf cart chargers do not have a cooling fan...they cool by convection...so it is important that they not be placed where air flow is an issue. My neighbor who is a worry wart uses an external small fan that blows on the back of his charger just because...I have never had a problem.
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Unread 06-12-2015, 12:16 PM   #3
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

I realize they have a heat sink in the rear of the charger bolted to the metal. What I was concerned about was the temperature when it charges the 4 12v batteries as it gets even hotter. I believe the smaller 17 amp transformer charger was "underengineered" for the large 12v batteries. CC got cheap with the later model smaller chargers the old ones would easily put out 25 amps and the diodes ran cooler. We will probably end up replacing the 12's with the 8's.
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Unread 06-12-2015, 01:48 PM   #4
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

I'm not a battery expert - but in my mind, since 12's actually hold less energy/reserve than 8's; they would be arguably easier to recharge than 8's. The 12's may be "big physically" but the the lead content is actually less/cell. If there is heat-generating resistance to re-charging them - its probably not their size. My guess would be its something else (like one battery has a dead cell and the others are being overcharged to compensate).
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Unread 06-12-2015, 05:42 PM   #5
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

Total voltage is all that matters really here. If you have 4 12's or 6 8's or 8 6's they all charge at roughly the same current. Charge time will vary depending on how much the batteries need.
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Unread 06-12-2015, 11:56 PM   #6
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

Check this out...
Attached Images
File Type: jpg charger temp.jpg (414.7 KB, 0 views)
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Unread 06-13-2015, 02:55 PM   #7
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Talking Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

See..just what I said...no issues...lol...charge on!
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Unread 06-19-2015, 10:18 AM   #8
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

Total voltage is NOT the only thing that matters here you can have the same voltage and not have the same current drawing ability. There is more plate area in the 6 eights than the 4 twelves. Many people are experiencing shorter life with the 12v. The Charger is fine the temp was only 125.8 degrees. I have an accurate type k thermocouple meter I used in Industrial Electrical Troubleshooting. I have a Fluke Meter and you can buy the accessories from Fluke if you go to their site and look for distributors. Fluke are expensive meters but it's all I have used since 1977.
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Unread 06-19-2015, 10:33 AM   #9
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

These chargers rely on the OBC to determine how much charge is required, they have algorithms to accommodate charging of the batteries. The 4 12v's have less plate surface area thus providing way less usable amp hours than the 8v batteries. So they will not last as long if you use them as much as the 8's.
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Unread 06-19-2015, 12:13 PM   #10
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Default Re: Changing 4 twelve volt batteries for 6 eight 6 volt batteries

I used your #2 gauge wire size versus #4 gauge as a class project. Assuming a 1 foot cable. The resistance per 1000 feet ! for the 2 ga. is .156 ohm per 1000 feet. For 4 Ga. is .248 ohm per 1000' At 48v supply with a current draw of 200 amps the voltage drop for the 4 ga. is .102 volt for the 2 ga. it's .064 volt. Total voltage at load would be 47.89 volts for the 4 ga. and 47.93 volts for the 2 ga. at 1 ft of cable.
When using a high current controller, be aware a stock motor may not be able to handle the heat generated. Going from a stock 275A controller to a 600A, the amount of heat generated in the motor will go up about 5 times compared to a stock controller.With controllers 400A and above, the car wiring needs to be changed from #6 to a minimum#4 Gauge cable. Going to a #2 is a waste of money,but if you got the money,I guess it's no problem. Notice I used a 48v supply to the motor,when in reality you may have a little more. The standard golf cart motor runs about 3600 rpm at about 4000 they will start to overheat. AT about 6000 to 7000 they will turn to junk eventually.
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