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Unread 06-10-2010, 12:44 PM   #1
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Default How to wire a voltage reducer

I have an 05 CC 48 volt IQ cart that has been totally redone to a DS cart. When I removed the voltage reducer it wasnt connected. It doesnt have a brand name but it looks similar to the one that is sold from BGW. On one end it has a 10 awg wire with a 5/16" lug and on the other end it has a 10 awg black wire that has a single stakon with a double wire coming out of it. That side has shrink tubing covering the stakon and I didn't want to cut it off if possible.

My question is how does this wire up to batteries and what is the 12 volt output?

Thanks
ATV-RVr
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Unread 06-10-2010, 03:01 PM   #2
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Default Re: How to wire a voltage reducer

Common sense dictates that a voltage reducer needs 2 input wires and 2 output wires. Can you open the unit up and check inside?
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Unread 06-10-2010, 04:03 PM   #3
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Default Re: How to wire a voltage reducer

Thanks for the reply, No you cant open it up. It is sealed in epoxy. My guess and this is only a guess...is the mounting bolts act like a common ground (of course a wire to the mounting bolt would have to be ran to the neg terminal of 2 of the batteries 16 volt to 12 volt) If that is true then the wire coming off the otherside (with the stakon) is the output and the wire with the 5/16"lug goes to the positive of the 2 batteries used. Voltage Reducer 1.JPG

Voltage Reducer 2.JPG
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Unread 06-10-2010, 04:07 PM   #4
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Default Re: How to wire a voltage reducer

Quote:
Originally Posted by gornoman View Post
Common sense dictates that a voltage reducer needs 2 input wires and 2 output wires. Can you open the unit up and check inside?

While common sense may dictate it, Its not always true. I bought a cart with the type voltage reducer he is talking about. The wire with the eyelet on mine goes to the negative terminal. Bare in mind that mine is also a 16v to 12v not a 48v to 12v reducer. So it takes its power off just 2 batteries. You power what ever 12v accessory off the positive side of the 2 batteries and the negative side goes to the end of the reducer with the stake ons. Odd set up but it does work. I prefer a reducer that takes off the entire pack, but this is what was on the Cart.


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Unread 06-10-2010, 04:11 PM   #5
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Default Re: How to wire a voltage reducer

Quote:
Originally Posted by ATV-RVr View Post
Thanks for the reply, No you cant open it up. It is sealed in epoxy. My guess and this is only a guess...is the mounting bolts act like a common ground (of course a wire to the mounting bolt would have to be ran to the neg terminal of 2 of the batteries 16 volt to 12 volt) If that is true then the wire coming off the otherside (with the stakon) is the output and the wire with the 5/16"lug goes to the positive of the 2 batteries used. Attachment 34179

Attachment 34180

Yup Thats just like mine...DO NOT use the mounting bolt as a ground!!! Frame is NEVER used as a ground.

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Unread 06-10-2010, 04:25 PM   #6
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Default Re: How to wire a voltage reducer

Thanks Cart Trader for the replies....it all makes sense now.
This is getting scarey!!!
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Unread 06-10-2010, 05:02 PM   #7
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Default Re: How to wire a voltage reducer

So much for theories! I learn something everyday here!
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Unread 06-10-2010, 06:12 PM   #8
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Default Re: How to wire a voltage reducer

Quote:
Originally Posted by ATV-RVr View Post
I have an 05 CC 48 volt IQ cart that has been totally redone to a DS cart. When I removed the voltage reducer it wasnt connected. It doesnt have a brand name but it looks similar to the one that is sold from BGW. On one end it has a 10 awg wire with a 5/16" lug and on the other end it has a 10 awg black wire that has a single stakon with a double wire coming out of it. That side has shrink tubing covering the stakon and I didn't want to cut it off if possible.

My question is how does this wire up to batteries and what is the 12 volt output?

Thanks
ATV-RVr
Do you think there may be a reason that someone wouldn't have this reducer connected... Is it worth the chance to hook it up and find out that you might fry something? Maybe time to purchase one that does take the total battery pack voltage down to 12v. Just a thought...
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Unread 06-10-2010, 08:33 PM   #9
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Default Re: How to wire a voltage reducer

need to be careful that voltage reducer i do beleive the single 10 gage wire goes to the controller.....................................
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Unread 06-10-2010, 09:58 PM   #10
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Default Re: How to wire a voltage reducer

the voltage reducer you pictured bolts to the frame on the inside of the I-beam behind the battery pack on the driver's side of the car. the single black wire with the 5/16 ring connect goes to the B- post of the controller (or you can run it to the 48v- post of the battery pack, which SHOULD be the negative post of the rear battery on the Driver's side). The "split" stake on connectors are the Ground for your accessories and you can either connect it directly to your accessories or (as the manufacturer does) connect it to a "gang" ground block. You will then tap your positive from the positive post on the front battery on the driver's side of the cart (yes, I know that would normally be 16 volts, but that "reducer" takes 16-18 volts and reduces it to 12.7 volts constant).

I have no idea why Club Car uses this setup, but it does work. As others have already mentioned though, a setup that pulls from ALL 6 batteries is far better for the overall lifespan of your battery pack.
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