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Unread 11-09-2018, 01:16 PM   #71
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Default Re: DIY Lithium Conversion

I have a 250 amp fuse on my 48v cart with an ALLTRAX 300 (360 max) amp controller.

I put a 300 amp fuse on the 36v cart with a Curtis 400 amp controller.

I just ordered 30 amp fuses for the charger cables, currently the charger cables are still on the larger fuses.
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Unread 11-09-2018, 03:29 PM   #72
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Default Re: DIY Lithium Conversion

That sounds like a good idea.
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Unread 11-24-2018, 08:02 PM   #73
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Default Re: DIY Lithium Conversion

Update on the 36v pack... Range is not good with just the eleven 45ah cells. We are going to double the pack with another eleven cells in parallel. Buddy was driving the cart around Fort DeSoto and his volt meter isn't illuminated. Driving back to his campsite and the cart died. No idea what the voltage was. He pushed it back and plugged it in. Cart seems to be fine. When he gets back I'll check his cells to see if any look swollen or have a different at rest voltage than the rest.

My cart still seems good. I did increase the pack voltage when I went lithium so I have more watt hours available. I'm still going to double my pack for the parade, but I have had no range issues.

Also, someone asked about my charger so I thought I'd post here. It is a Meanwell ENC-360-48. If I remember correctly it charges at 5 or 6 amps, not much, but since lithium charge more efficiently and there's no electrolyte to boil it's not an issue. The charger has 4 dip switches on the back. I set it to gel batteries as they have the lowest voltage and it charges to 56.6v or so. I'm going to see if the AGM setting gets closer to my 57.6v target but 56.6v is good enough for now. That charger is $90 to $100 plus shipping. I've been using it for about a month and no issues. It does have a lithium ion setting, but that will go to full max V for my pack and I don't want to go that high.
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Unread 12-08-2018, 08:19 AM   #74
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Default Re: DIY Lithium Conversion

He had no swollen cells and all charged back to correct voltages, so he aged his pack, didn't kill it. I gave him an illuminated volt gauge for him to install too... No need to do this again.

He opted to go with two more volt packs. So we'll have 47ah x3 in his cart using 11 cells each. That'll leave 3 cells left over so he might attempt to use those for a 12v power source and be completely lead free.

For my 58.8v pack I was worried about the upcomming parade pulling the float. So i bought some stock size wheels to help with the long slow speeds and I bought a second pack.

I hooked up to the trailer with nothing on it and I could tell right away that wheelies would be frequent... I mounted the side panels, seating, generator platform, etc. I haven't put in the second battery in the cart yet, but with me standing at the front of this trailer and bouncing I was able to make the carts front wheels lift off the ground.... I may need to mount some weights on the front like they do on tractors! I made the seating on the float as far back as possible and put the generator actually off the trailer behind it on a platform I built. We'll see...
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Unread 12-14-2018, 08:08 AM   #75
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Default Re: DIY Lithium Conversion

I put in the second pack, connected the ground wires and let the packs equalize via a 100 watt incandescent bulb acting as a resistor between the two. Didn't take long and the two packs are the same V now.

I made an easier connection to the second pack. I took one of these ANL fuses:
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
and used that to connect to the pack by drilling a 1/4 inch hole in the metal upright at the 14th cell and using a 1/2 inch long 1/4 inch bolt to connect that fuse. There's not much space, but it worked. Now I have a fuse on each pack that leads to the correct ANN fuse:
http://www.buggiesgonewild.com/pictu...ictureid=27949

I know the ANL fuse is slow-blow and the ANN fuse is a very fast blowing fuse, but the full power of everything goes through the ANN. So if there's something after the pack, it's on the correct ANN. I added the ANL to save one battery bank from the other if need be.

I'm letting the two packs sit for a bit to 'settle out' before connecting the two together. The second pack did not come with the plastic cover, so I need to build that. Just haven't decided on the best method yet. I'm leaning towards cutting a piece of wood the same dimensions as the pack then using a heat gun to form a piece of plastic around the wood. Remove the wood and then use the plastic for the cover. We'll see.

The parade is tomorrow and I was unable to use stock height tires. They hit the lift on the front of the cart... I'm hoping to get the second pack connected and the cart decorated. The float is already done. Last thing is for me to then mount two 20 lb weights on the front axle of the cart... Trying to help keep the front end down now that the cart is 400 lbs lighter. The front axle is furthest from the fulcrum so that will give the best leverage. Fingers crossed!
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Unread 12-20-2018, 12:02 PM   #76
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Default Re: DIY Lithium Conversion

How did the parade end up going with the trailer?
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Unread 12-26-2018, 04:06 PM   #77
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Default Re: DIY Lithium Conversion

The parade went great! Better than expected actually. On the trailer were 4 moms, one dog and 8 kids while mother-in-law and I on the cart. started out at 56.6v and finished at 53.4v. I made a post here:
Christmas Float - Lights

I also had another night out looking at lights with a total of 5 adults and 8 kids the second night, but it was colder so I drove slower and we took a longer route. Still did well and motor never overheated.

I had a heck of a time balancing all the cells though... When I was preparing to install the second half of the battery pack, I partially charged the 14 cells for traction to 3.99vpc and left the other 4 cells uncharged/unused. When I wired it in, I wired the 4 uncharged and 10 of the charged cells in... Since the volt pack is one long module I could either go through the effort to re-make a new connection or charge up the uncharged cells individually. I have a "Fully Automatic Schumacher 6v/12v charger" that I knew would overcharge a single cell but figured I could watch like a hawk and get those cells brought up. They were at 3.55vpc. I connected, checking the V very frequently and my "6v/12v" charger, it stopped charging a single cell at 3.74vpc! I was able to individually bring all 4 cells up to 3.74vpc, ran the cart a little, then just charged those 4 cells back to 3.74vpc. Running the cart brought the 3.99vpc cells down and then I charged up the other 4 to bring them all up to par. Took 3 cycles of "using/charging" before I got to the point where all 14 cells in the traction pack were within 0.01v of each other.

Now I just need to make some plastic covers for the second pack.
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