A little help on a 48 volt upgrade path please.

h20fow1er

Years ago (2009) I started down the path of upgrading my stock 95 Medalist. 2 years ago I got busy and the cart was neglected. Now its time to clean it up and make things right.

The idea was that it would be upgraded to 48 volt whenever the battery pack died, and I would upgrade the motor whenever it cratered. Goals of this project were a family cart to cruise the neighborhood, let the kids drive it to the pool and back, some light golf usage, and something to run around the woods and fields for hunting and cattle work. I know hills are subjective to terminology - but I have to face them.


As it sits now,
- DEAD and NASTY 36 volt system. Exide "seconds" that came with the cart.
- Alltrax 4855 (500 amp) controller
- 4 gauge ? cables throughout.
- what appears to be a 50 Amp solenoid (White Rodgers70-120224-5 36 volt )
- Stock motor

I have a 48 volt 400 amp solenoid (MZJ-400) that I picked up early in the build. its sitting on the work shelf waiting.

Question 1 - Am I correct in that all I need to complete this project

- 48 volt battery pack
- New charger
- FNR upgrade?
- possibly new cables?

Question 2a - This has the anderson plug. I'm looking at 6 Trojan T-875's. I don't have a lot of options locally and $ wise these make the most sense. So what charger should I be looking at? DPI or Eagle? It appears both can come with the anderson plug.


2b - The way I see it I have 2 options, 6-8 volts or 8-6 volts. Either way I am going to have to purchase a battery charger. Rather that be another 12 volt to help maintain batteries 1 and 2 while using the 36 for batteries 3-8 OR a single 48 volt charger. I like the added range, but I hate having a battery in the bagwell. I like the extra 12 volt battery for accessories instead of running of the pack. To me running the accessories off the pack totally defeats the value of the added range of 8 batteries. What are the thoughts here?

BGW

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DIRTPIT HC

When I changed from 36 to 48 volts, I went with 6- 8 volt batteries. It made more sense for me to just pull 6 out and drop 6 back in. I went with the dpi charger and am glad I did. No problems and works very well. I also installed a voltage reducer to run accessories. That way it pulls from the entire pack. All my stuff came from ScottyB at carts unlimited. He is top notch and sells good stuff at good prices and great customer service.

JohnnieB

1. Yes to all.
FNR upgrade: http://www.cartsunlimited.net/F_R_Switch_Upgrades.html or Reversing Contactor: http://www.cartsunlimited.net/Reversing_Contactors.html
4Ga cables minimum - All 13 of them.

2a. DPI is the best bang for the buck, plus has float charging: http://www.cartsunlimited.net/48v_Battery_Charger.html

2b. Using 6 x 8V 170AH batteries will give you about the same range as a stock battery back (6 x 6V 225AH batteries), so going with higher AH 8V batteries will up the range. (190AH is +11.8% and 204AH is +20% -- see attached chart) Using 6 x 8V leaves the space in front of the driver side tire for for the 12V accessory battery.

If you replace the F/R assembly with a reversing contactor, you will have room in front of the controller for the eighth 6V battery and unless you have a high power halogen light and a huge audio system and run them all the time, a voltage reducer won't reduce your range all that much.

Another option is to go to 42V (7 x 6V) and put a small 12V accessory battery between the controller and F/R assembly.

Attached Images

48V kWh Comparisons.JPG (105.4 KB, 0 views)

kernal

I went with the 6x8's also. DPI accusense charger is nice. Relatively small, uses modern technology and floats the batteries when charge is complete.

For 12v I use a 35ah glass mat power chair battery. Maintenance free. Fits in the space on the drivers side with room to spare. Used a standard battery hold down from auto parts store. Didn't even need to drill a hole. Powers lights, stereo and aux power. I have run the sound nearly all day and not stressed the battery at all. Charge it with a $30 maintainer. In its 4th year now.

JonnieB's math suggests that 6x 8v 170ah batteries will give the same range as 6x 6v 225ah batteries. I have proven to myself that this is true in actual use. However, mine is on the street only with street tires.

48v changes the carts performance considerably. Powerful and fast. Something to think about with kids. You may discover some weaknesses in your brakes also.

For F/R switching the heavy duty cam is fine for me.(street) If it ever gives me trouble I will go to reversing contactors.

h20fow1er

Thank you JohnnieB, I've been using those number as a guide when shopping. they have been most helpful! Unfortunately I live in a location where battery golf carts just don't seem to be that popular - and replacement choices are very limited. The only 2 batteries within 30 minutes of me (outside of SAMS) are the crown CR 165 and the Trojan 875. Or I can drive an hour and get the US 8vGC. I've yet to fins anyone that carries the Crown 190's, or Trojan 890's.

Kernal - kids are 13 and 14, one has been driving quads since he was 4, the other is driving cars. Power of the cart is a concern, but at some point I have to hope common sense and experience prevails - I know it won't everytime. Your aux battery set up is almost exactly what I have running my cooler stereo. and one that I will probably go with in the cart.

kernal

Meant no offense. Around here 13 year olds can drive carts legally, even on the streets with supervision.

h20fow1er

none taken. Heck, I'm my fathers kid and I'm dang near 40. :)

Sir Nuke

h20fow1er.....Johnnie mentioned 4 ga cables MINIMUM.....which is TRUE. HOWEVER you have a 500 amp controller, and I know Scotty recommends 2 ga. cables for 500 amp....which is exactly why that is what's in my cart. as you can see in my sig, I have all the pieces parts you have/want (other than my motor, and mines still 36v) and I use my cart like you intend to use yours. AND like you, when my pack dies in a couple of years, I'm going 48v as well, and everything I have is all 48v compatible already.

Great white north

If you want maximum range and life of battery go with 8 -6 volt set up
Best way to go I have 260 amp /hr .Crowns .. ... Yes. You have a little extra weight
But that is offset with life of battery and range .. ... I would not even consider going 8 volt
Go with DPI charger ... And auxiliary 12 volt battery in bag well

HiTechRedNeck

Counterpoint....

Go with voltage reducer.
1) pulls from entire pack evenly-- no balance problems.
2) Saves weight as compared to Spare battery.(and space)
3) No additional maintainer/charger needed.
4) power use of acc. is negligible when compared to motor power usage.(in most cases.. Extreme audio system used for hours at a time with lights might affect range)

In our experience the power reducers have little or no effect on battery life.