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Unread 08-21-2014, 11:46 AM   #11
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Default Re: Relay for voltage reducer not working

Make sure it is a DC relay for the coil. As far as the converter output that is another issue, lets get it to start with the key switch first. Check and make sure it is DC.

Your right Sergio, I said 30A when really it is only switching power to turn the converter on not to carrying the load.
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Unread 08-21-2014, 11:51 AM   #12
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Default Re: Relay for voltage reducer not working

When You get your hands back to the relay, disconnect all wires from it then test the resistance on the coil terminals. It should be around 2k ohms, but the important part is that the coil is not open (no resistance).

Then plug the relay coil straight to the pack positive and negative, You should feel the relay click.

I am not sure why there would be such a larger voltage drop at the key switch, Do you get full pack voltage on the "Green Wire" at the key switch when the switch is Off?
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Unread 08-21-2014, 11:52 AM   #13
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Default Re: Relay for voltage reducer not working

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Originally Posted by scooterman View Post
Make sure it is a DC relay for the coil. As far as the converter output that is another issue, lets get it to start with the key switch first. Check and make sure it is DC.

Your right Sergio, I said 30A when really it is only switching power to turn the converter on not to carrying the load.
Searching that part number on TE website shows "restricted item". I'm thinking it's a charger relay that is AC switching to DC. That would explain it or not?
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Unread 08-21-2014, 11:56 AM   #14
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Default Re: Relay for voltage reducer not working

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Originally Posted by Sergio View Post
When You get your hands back to the relay, disconnect all wires from it then test the resistance on the coil terminals. It should be around 2k ohms, but the important part is that the coil is not open (no resistance).

Then plug the relay coil straight to the pack positive and negative, You should feel the relay click.

I am not sure why there would be such a larger voltage drop at the key switch, Do you get full pack voltage on the "Green Wire" at the key switch when the switch is Off?
Never heard the relay click originally when I had it hooked directly to the pack. Only when I reversed polarity did it click. I'm getting zero voltage at the "only other terminal - not blue". I'm smelling previous owner wiring modifications.
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Unread 08-21-2014, 12:06 PM   #15
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Default Re: Relay for voltage reducer not working

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Searching that part number on TE website shows "restricted item". I'm thinking it's a charger relay that is AC switching to DC. That would explain it or not?
If it is an AC relay switching DC it will not work, you are correct.

My question is does the converter even need a relay on the start circuit or can you wire it directly to the key switch? How much does the power on for the converter use?
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Unread 08-21-2014, 12:10 PM   #16
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Default Re: Relay for voltage reducer not working

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If it is an AC relay switching DC it will not work, you are correct.

My question is does the converter even need a relay on the start circuit or can you wire it directly to the key switch? How much does the power on for the converter use?
Don't know. It's a cheap Chinese box, with just the wiring diagram included. Based on running it through a 24VDC 10-amp switch without blowing a fuse or overheating the switch, I'd say it's probably pretty small. Think the stock switch could handle it?
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Unread 08-21-2014, 12:25 PM   #17
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Default Re: Relay for voltage reducer not working

Not sure, without knowing the relay is good protection. You could test it briefly but I just don't trust those chinese converters.
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Unread 08-21-2014, 12:32 PM   #18
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Default Re: Relay for voltage reducer not working

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Not sure, without knowing the relay is good protection. You could test it briefly but I just don't trust those chinese converters.
My feelings exactly. I don't like the idea of constant power-on on any component, regardless of nationality.

If the key switch won't handle it, I'll order another relay. If the key switch won't handle it, I'm sure the marine switch is not long for this world either. Thanks for the help.
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Unread 08-21-2014, 12:42 PM   #19
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Default Re: Relay for voltage reducer not working

Don't get 36v power straight off the Key switch to power the converter, it was not designed for that. It will cause problems with newer controller carts, and even on the older models will cause more wear on the key switch.

How many wires on Your key switch?

With the switch off, only one of the wires should have power, and it should be pretty close to pack voltage or you need to find out where the drop in voltage is happening.

Some relays have a flyback diode built in, but I never seen it on these panel mount relays... then again, until You see the actual part # on the relay, it may be an "equivalent" model.
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Unread 08-21-2014, 12:55 PM   #20
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Default Re: Relay for voltage reducer not working

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Don't get 36v power straight off the Key switch to power the converter, it was not designed for that. It will cause problems with newer controller carts, and even on the older models will cause more wear on the key switch.

How many wires on Your key switch?

With the switch off, only one of the wires should have power, and it should be pretty close to pack voltage or you need to find out where the drop in voltage is happening.

Some relays have a flyback diode built in, but I never seen it on these panel mount relays... then again, until You see the actual part # on the relay, it may be an "equivalent" model.
Key switch has 2 wires. I left the converter on for a good while last night, with the headlights and taillights on. The 24vdc switch held-up as did the fuses. Maybe I'll just run it that way until it gives up the magic smoke, then replace it with a relay...hopefully the right one this time. So I need a relay that is 36vdc on the coil (switching) side? What voltage for the power side?
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