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Old 11-26-2012, 12:37 AM   #1
widowmaker
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Default PDS 36V- 48V conversion

It's time to get new batteries in my cart.

I thinking of doing the following.

I'm new to this stuff but I am asking for suggestions so I do it once. If this is wrong way about it please speak up. Thanks guys.

I have already upgraded to all new 4 gauge wires to motor, batteries and controller.

going to get hydraulic front disc brakes to start then

6 new t -875 batteries

1 new DCX400 controller

1 New 200 amp solenoid

1 new 48 charger

It is a lifted pds cart with 23" tires, 10 inch wheels a simple spindle lift up front with block type lift in the back. The cart has a rear seat that is used at times. I don't care about speed just torque.
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Old 11-26-2012, 06:56 AM   #2
Dela
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Default Re: PDS 36V- 48V conversion

Order from ScottyB and check out JohhnieB sleeper thread, they'll set you straight like V8
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Old 11-26-2012, 08:18 AM   #3
JohnnieB
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Default Re: PDS 36V- 48V conversion

Welcome to BGW!

Asking questions first is the right way to do it.

I've got some food for thought, but I'm up against the clock right now.
I'll be back later this afternoon.
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Old 11-26-2012, 12:35 PM   #4
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Default Re: PDS 36V- 48V conversion

I'm back!

Just about everything you do to an electric golf cart is a give and take compromise.

Examples:
The 23" tall tire give you 22% more speed than the stock 18" height but take away 22% of the stock torque.
Going from the stock 300A PDS controller to a 400A aftermarket controller increase torque by about 33%, which will offset the torque lost by the tall tires.
Net torque gain will be about 10% over stock.
And you will get more speed since the aftermarket controller does not limit motor RPM to about 4400.

It takes the same amount of energy to move a cart, regardless if the energy is delivered to the motor at 36V or 48V, however more amps are need at 36V than at 48V to deliver the same energy. A set of six T-105 batteries store about 9kWh of energy and set of six T-875 batteries also stores about 9kWh of energy, so the run time will be about the same using a 400A controller at 36V or at 48V.

One way to gain torque (and reduce speed) is to go to a lower tire height.
You have to have at least 10" if you are going to install disk-brakes, but tires that fit on 10" rims do come in lower profiles.
(IE: a 205/50-10 is about 18.5'' tall and a 205/65/-10 is about 20.7" tall)

There are many variables that have to be taken into account when planning a build. The trick is determining what you want the end product to be and build towards that goal.

Sounds like you are planning ahead. Scotty (Carts Unlimited) has some good planing info on his website. http://www.cartsunlimited.net/Custom_Options.html

I was looking for run-time rather than Speed or Torque, but I will gain in all three with my set-up.
By using 7 high capacity batteries, I'll be carrying about 11.5kWh instead of the typical 9.0kWh.
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Old 11-26-2012, 01:46 PM   #5
widowmaker
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Default Re: PDS 36V- 48V conversion

Cool thank you Johnnie,

I have been reading up on Scott B's website. I was planning to keep with the stock motor for now 36v.

Probably where I will get most of my parts from him since he is close by.

Am I understanding correctly that the motor will last longer (longevity not run time) by using 48 volts?


I understand basic electronic, as voltage drops, current goes up and tend to get things hot, like motor windings and battery cables?

By keeping a higher average voltage to the motor it will run cooler?

Battery cost is about the same and the only other item i will need is a new charger.

First thing I ordered last night was a DVM and plate for the dash where the key and fwd/reverse switch go so I know where I'm at. Thanks Scotty B
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Old 11-26-2012, 02:05 PM   #6
widowmaker
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Default Re: PDS 36V- 48V conversion

Was reading Johnnies build.

Which is going to be better for my cart the 200/800 solenoid or the 400/1000?
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Old 11-26-2012, 02:34 PM   #7
Dela
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Default Re: PDS 36V- 48V conversion

go big or go....

what I'm learning and from what I gather - more amps will give more protection, more protection = $$ saved.

go with the 400/1000 - if you don't now you'll wish you did in the near future.
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Old 11-26-2012, 02:45 PM   #8
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Default Re: PDS 36V- 48V conversion

Quote:
Originally Posted by widowmaker View Post
Was reading Johnnies build.

Which is going to be better for my cart the 200/800 solenoid or the 400/1000?
The higher capacity solenoid not only has larger contacts but they are higher grade material. The result will be a longer useful life at any amperage.
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Old 11-26-2012, 03:15 PM   #9
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Default Re: PDS 36V- 48V conversion

Quote:
Originally Posted by widowmaker View Post
Cool thank you Johnnie,

I have been reading up on Scott B's website. I was planning to keep with the stock motor for now 36v.

Probably where I will get most of my parts from him since he is close by.

1. Am I understanding correctly that the motor will last longer (longevity not run time) by using 48 volts?

2. I understand basic electronic, as voltage drops, current goes up and tend to get things hot, like motor windings and battery cables?

3. By keeping a higher average voltage to the motor it will run cooler?

4. Battery cost is about the same and the only other item i will need is a new charger.

5. First thing I ordered last night was a DVM and plate for the dash where the key and fwd/reverse switch go so I know where I'm at. Thanks Scotty B
1. Heat is killer and entire system tends to run cooler on 48V than 36V because fewer amps are passing through it for the same workload.

2. Actually current decreases through a constant impedance as applied voltage decreases, but to maintain the same power, current must increase when voltage decreases. It's the Amps x Volts = Watts formula that applies rather than Amps x Ohms = Volts.

3. More or less true. The higher the voltage, the fewer amps needed to transfer the same power. This is why the power companies use extremely high voltages (IE: 500KV) to move power from the power plate to the consumer. Of course, the real reason is because any energy lost as heat cuts into their profit margin.

4. I use the DPI charger.

5. The DVM battery meter will drive you a bit bonkers at first because if fluctuates quite a bit as you drive, but once you get used to it, it is actually giving you some good info while it is fluctuating.

The faster you draw amps out of the battery pack, the lower the pack voltage drops.
Keep the voltage under load above 1.75V per cell and your batteries will like you a lot better.
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Old 02-02-2013, 09:38 PM   #10
widowmaker
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Default Re: PDS 36V- 48V conversion

Ok, I got the conversion done! Definitely woke up my cart. The 6 volt t-125s that I took out were 5 years old.

Scotty B set me up with an Alltrax 400 amp controller, a 200/800 solenoid and DPI charger. Then I picked up a set of 6 - 8 volt US batteries.

So far it goes 28mph! Pretty fun, really not necessary to go that fast IMO. Thank goodness I added front disc brakes already.

When I barely touch the gas it seems to really come on full steam especially in reverse. Is there a way to soften the throttle response? I feel like it might break something. I'm hoping I can change something in the controller?

Thanks
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