Reducer wiring problems

wards75 · 09-15-2016, 10:44 AM

Ok guys, so I bought a voltage reducer off eBay (300w/25a) to step my 48v pack down to 12v for accessories.
I'm following a wiring diagram gained from here, that uses the key switch to power it so there's not a constant parasitic load on it.
I'm going to a Blue sea fuse panel w/ a ground bar.
I hook everything up temporarily to make sure all is working properly before mounting and cleaning up, turn on my key switch and naturally there's a spark accompanied by smoke at the switch and solenoid and the green wire from my switch is cooked as well as the red wire on my solenoid.
Looking at the wiring diagram for my cart:
(2001 CC DS 48v Series)

It shows the green wire going to the solenoid and the red to the reverse buzzer (My buzzer is disconnected) but I see no green wire at the solenoid, not sure where it goes or what happened but I'm extremely apprehensive to try again. I disconnected the reducer wiring and checked and still have power to solenoid and cart still operates.
My reducer has 4 wires positive in/out & negative in/out.

I'm sure it's the wiring, any suggestions?

Converter diagram I'm using:
20160424_230950-1-1.jpg

Burnt wires:
20160915_111156.jpg
20160915_111232.jpg

scottyb · 09-15-2016, 10:56 AM

Does the cart ignition switch have a positive or negative feed?

wards75 · 09-15-2016, 11:19 AM

I'm not exactly sure scottyb and not around the house right now, I have my volt meter hooked to it and it powers when the switch is turned on, so assuming it's a positive feed?

wards75 · 09-15-2016, 11:23 AM

So i might have to reverse my trigger for the reducer to the positive side instead of the negative?

Now I'm gonna get a little confused on landing the other wires for the reducer and fuse box :o

scottyb · 09-15-2016, 11:33 AM

Some of the CC had a (-) key switch circuit. One of the regular CC techs can answer for your yr cart. But you actually have the answer if you remember where the 2 meter wires are connected.

wards75 · 09-15-2016, 04:42 PM

I'm thinking I put my trigger wire on the wrong side of the ignition switch...I had it on the side that's hot when you turn the key on. Sounds like what I did doesn't it? 🙁
Either way, now I've earned myself the opportunity to re-run 2 new wires, the burnt green one and red one..isn't that peachy.

09-15-2016, 10:44 AM	#1
wards75 Getting Wild Join Date: Oct 2012 Location: Eastern NC Posts: 141	Reducer wiring problems Ok guys, so I bought a voltage reducer off eBay (300w/25a) to step my 48v pack down to 12v for accessories. I'm following a wiring diagram gained from here, that uses the key switch to power it so there's not a constant parasitic load on it. I'm going to a Blue sea fuse panel w/ a ground bar. I hook everything up temporarily to make sure all is working properly before mounting and cleaning up, turn on my key switch and naturally there's a spark accompanied by smoke at the switch and solenoid and the green wire from my switch is cooked as well as the red wire on my solenoid. Looking at the wiring diagram for my cart: (2001 CC DS 48v Series) It shows the green wire going to the solenoid and the red to the reverse buzzer (My buzzer is disconnected) but I see no green wire at the solenoid, not sure where it goes or what happened but I'm extremely apprehensive to try again. I disconnected the reducer wiring and checked and still have power to solenoid and cart still operates. My reducer has 4 wires positive in/out & negative in/out. I'm sure it's the wiring, any suggestions? Converter diagram I'm using: 20160424_230950-1-1.jpg Burnt wires: 20160915_111156.jpg 20160915_111232.jpg

09-15-2016, 10:56 AM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Reducer wiring problems Does the cart ignition switch have a positive or negative feed?

09-15-2016, 11:33 AM	#5
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Reducer wiring problems Some of the CC had a (-) key switch circuit. One of the regular CC techs can answer for your yr cart. But you actually have the answer if you remember where the 2 meter wires are connected.

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09-15-2016, 11:19 AM	#3
wards75 Getting Wild Join Date: Oct 2012 Location: Eastern NC Posts: 141	I'm not exactly sure scottyb and not around the house right now, I have my volt meter hooked to it and it powers when the switch is turned on, so assuming it's a positive feed?

09-15-2016, 11:23 AM	#4
wards75 Getting Wild Join Date: Oct 2012 Location: Eastern NC Posts: 141	So i might have to reverse my trigger for the reducer to the positive side instead of the negative? Now I'm gonna get a little confused on landing the other wires for the reducer and fuse box :o

09-15-2016, 04:42 PM	#6
wards75 Getting Wild Join Date: Oct 2012 Location: Eastern NC Posts: 141	I'm thinking I put my trigger wire on the wrong side of the ignition switch...I had it on the side that's hot when you turn the key on. Sounds like what I did doesn't it? 🙁 Either way, now I've earned myself the opportunity to re-run 2 new wires, the burnt green one and red one..isn't that peachy.