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Old 01-23-2011, 07:07 PM   #1
wizardket
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Default Considering Kelly 24-48 V 400 A Controller

I have a 96 TXT 36v cart I just got last month. I being a glutton for punishment, have torn it down to the ground. I fixed the micro switch that was keeping it from running and replaced 5 of the 6 batteries with T105's. I had the frame sand blasted and am painting it today with POR-15. I am having trouble deciding if I want to upgrade to 48v. It would require a new controller, charger & matting plug, contactor and HD F&R mod. That is a fare chunk of coin. I really will only use it around the house and take the trash to the street and pick up the mail. That is about .2 mile of gravel road each way and a steep for half that. No lift and has stock tires.

As I mostly want more torque for the hill, I was thinking of upgrading the controller to Kelly 24- 48 Volt 400 Amp PM Programmable Regen. This would let me be at 36v for now and maybe upgrade later. I have already rebuilt all the cables to at least #4. I will at minimum rebuild the F&R to HD but am also looking at a 400 Amp 36 Volt Reversing Contactor thought that depend on battery voltage.

Main question is on the wisdom of using the Kelly controller.
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Old 01-24-2011, 12:05 AM   #2
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Default Re: Considering Kelly 24-48 V 400 A Controller

After reading a lot of topics on the forum, I will be going with a HD cam replacement from Scottyb as this will give me freedom to change voltage without having to buy new contactors.
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Old 01-24-2011, 02:02 AM   #3
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Default Re: Considering Kelly 24-48 V 400 A Controller

While not get six new batteries instead of five?
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Old 01-24-2011, 11:43 AM   #4
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Default Re: Considering Kelly 24-48 V 400 A Controller

One was OK and @ $125 each I was not in a hurry. I will see how it does and am thinking of a Battery Desulfator. If it does not come up, I will replace it.
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Old 01-24-2011, 09:05 PM   #5
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Unhappy Re: Considering Kelly 24-48 V 400 A Controller

Quote:
Originally Posted by wizardket View Post
One was OK and @ $125 each I was not in a hurry. I will see how it does and am thinking of a Battery Desulfator. If it does not come up, I will replace it.
Well I got the 36v BatteryMINDer ordered today after pulling the trigger on the 07 EZGO PDS cart.

wizardket do you realize mixing old and new deep cycle batteries could cut your 5 new batteries life in half or more?

I lost an entire 48 volt bank of batteries due to one being defective. The bank lasted about two months and the defective one was new too. Since i cooked them I had to eat them.
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Old 01-24-2011, 09:11 PM   #6
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Default Re: Considering Kelly 24-48 V 400 A Controller

Quote:
Originally Posted by Gale Hawkins View Post
wizardket do you realize mixing old and new deep cycle batteries could cut your 5 new batteries life in half or more?
Wow, thats good to know. I have 2 that appear to be dying, full charge is 6.1 after driving for 1 mile it is at 5.95.
The others seem fine. But you are saying I need to replace all of them.
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Old 01-24-2011, 09:22 PM   #7
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Default Re: Considering Kelly 24-48 V 400 A Controller

The problem lies in the charging of old and new (or healthy and unhealthy) batteries in series. It is really hard on the good ones and like Gale said will reduce the new batteries to the level of the old batteries soon. The way this happens is simple to understand. The charging needs of the old batteries are greater than the new ones. The old ones need lots of amperage for long times and the new ones do not need so much charging...The new ones get over-charged which is harmful and results in irreversible damage. Soon they reach the level where they are equal to the old ones. .... hope that helps.
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Old 01-24-2011, 09:24 PM   #8
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Default Re: Considering Kelly 24-48 V 400 A Controller

& shy away from Kelly controllers.... I know they are the cheapest controller on the internet but, they do not have a very long track record and the record they do have is not so good....fyi
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Old 01-24-2011, 09:25 PM   #9
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Default Re: Considering Kelly 24-48 V 400 A Controller

Thanks Scotty, you are a great help.
It sucks that I need to replace all the batteries because 2 are going bad.
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Old 01-24-2011, 09:33 PM   #10
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Default Re: Considering Kelly 24-48 V 400 A Controller

Quote:
Originally Posted by Gale Hawkins View Post
do you realize mixing old and new deep cycle batteries could cut your 5 new batteries life in half or more?

I lost an entire 48 volt bank of batteries due to one being defective. The bank lasted about two months and the defective one was new too. Since i cooked them I had to eat them.
No, I did not. I just walked out and checked the pack. The old one is @ 6.19 and the new are @ 6.39 to 6.4. Looks like I will just have to replace it before I get the rebuild done. I was going to see if a desulfator could return it to 6.4.

I just pulled the trigger and bought the following from Scottyb:
  • 480 amp 36-48v Controller
  • HD 36v 200 amp Solenoid Kit
  • HD Switch Cam
  • LED in dash Battery Meter
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