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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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03-04-2014, 09:49 PM | #21 | |
Gone Wild
Join Date: May 2012
Location: S. Fl
Posts: 237
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
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03-05-2014, 06:43 AM | #22 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
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The DCX to PDS adapter cable is a plumber's nightmare and vulnerable to mechanical stresses, so I Ty-wrapped the control wires to a high current cable to reduce the amount of flexing they are exposed to. It also shows how much room is available in front of the DCX controller and Super-Duty solenoid. A 6V cart battery is very close to an 8V cart battery in length and width, and it doesn't look like a battery that size could be shoehorned in where the orange 12V accessory battery is located. |
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03-05-2014, 07:41 AM | #23 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
A stock PDS controller limits the motor to about 4400 RPM in Freedom mode, which is mathematically about 18 MPH on stock height tires and about 23 MPH on 22" tires, but the 4" taller tire costs you about 20% of the available torque, so the cart runs out of high end torque before it reaches that speed. And low pressure (<10 PSI) tires take more torque to turn than standard pressure (>20 PSI) tires. However, in Mild Hill mode, a standard pressure 22" tire would give you about 18-19 MPH. As for speed: It depends on the type tires you have. On 18.3" tires inflated to 22 PSI, I got 24 MPH with a DCX400 feeding a stock PDS motor from a 36V-225AH battery pack. (Range about 30 Mi.) When I went to a 42V-245AH battery pack the speed went up to 28 MPH and the range went to 36 Mi. Mathematically, that translates to 29 MPH @ 36V on 22" tires and 34 MPH at 42V, but you probably won't see those speeds in the real world due to the rolling resistance of the tires and other factors. ---------- For maximum lifespan, the batteries ought to be charged after each use, but you can estimate your cart's range by using the At-Rest voltage of the battery pack before and after a drive to the beach to ogle the bikinis. Basically calculate how many AH your cart uses per mile and divide that number into 50% of your battery pack's AH capacity. Rough the same way you estimate how far you car will go on a half tank of gas. |
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03-05-2014, 11:15 AM | #24 | |
Gone Wild
Join Date: May 2012
Location: S. Fl
Posts: 237
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
again thank you for your time. |
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03-05-2014, 12:01 PM | #25 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
Freedom mode is 4 beeps. Sounds like the tires are holding your top speed down some, but not quite as much as some of them do. A DCX controller and 42V still ought to get you into the mid to upper 20's, maybe even the low 30's. |
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03-05-2014, 05:11 PM | #26 | |
Gone Wild
Join Date: May 2012
Location: S. Fl
Posts: 237
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
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03-06-2014, 06:36 AM | #27 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
Alltrax is a company that builds aftermarket controllers and DCX is a family of controllers they make for Sepex (Separately Excited) motors, the type motor that is in your cart. The family members are DCX300, DCX400, DCX500 and DCX600, the numbers indicating the Amp rating. Unlike the Curtis 1206MX, the DCX family of controllers are designed to operate with pack voltages anywhere from 24V to 48V. Also unlike the Curtis 1206MX, the DCX family of controllers do not limit the max RPM of the motor, This feature alone will up the top speed of an otherwise stock PDS cart into the low to mid 20's. In addition, the DCX controllers are user programmable, so they can be tailored to better suit your needs. You have 22" tires, so you are loosing about 20% of the available torque. To regain that loss, you have to increase the Amps the motor can draw. The Curtis 1206MX is a 300A controller, so you need a controller with at least a 360A rating to offset the torque loss caused by the taller tires. A DCX400 is a 400A controller, so it would have a torque gain of 33% and when combined with the 20% torque loss from the tires, you would have a net torque gain of a bit over 10%. A DCX500 or DCX600 would up the torque even more, but they can deliver more amps than a stock PDS motor can handle on an ongoing basis, so a more robust motor would have to installed. (It will work, just not for long. Sorta like installing a Jimmy 471 under the carburetor of an otherwise stock engine.) ----------- The stock solenoid is rated at 85A continuous. At best, it is marginal for a 300A controller. In addition to the amp rating of the contacts, the coil will only operate over a narrow voltage range centered on 36V. If the voltage is too low, the contacts don't close properly. If the voltage is too high, the coil burns out. Some solenoids have coils that will operate over a wider voltage range. I'm not sure about other solenoids from other sources, but I know from personal experience that the Super-Duty 48V solenoid (400A continuous/1000A peak) that Carts Unlimited sells (scottyb), will operate at 36V and 42V, and other forum members are running it at 48V. So it is a good choice if you want run at 36V now and plan to upgrade the pack to a higher voltage later. Also, at 1000A peak, it will handle the amps passed by any controller that most people are likely to installed. ---------- Battery chargers have to match the pack voltage and have a charge profile compatible with the brand battery being charged. The DPI Accusense chargers have two main components, a step-down transformer and a PCB (Printed Circuit Board). The transformer used in the 36V version is too small to power a 42V PCB, but the same transformer is used in both the 42V and 48V versions. I had a 36V DPI and had to buy a 42V one when I went to 42V, but if I ever go to 48V, all I have to buy is the 48V PCB to convert my 42V charger to a 48V charger. Also, the DPI has user selectable charge profiles for different brands of batteries. ----------- Hope this helps. Like working on engines with carburetors, asking questions before jumping in is a good thing. |
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03-06-2014, 11:12 AM | #28 | |
Gone Wild
Join Date: May 2012
Location: S. Fl
Posts: 237
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
again thank you! |
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03-06-2014, 11:32 AM | #29 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
One thing I failed to mention, replace your high current cables. (All 10 of them)
Back in Jun-2011 when I got my 2008 PDS, the cables looked pretty good, but I found out they were pretty sick when I compared them to new set of 2Ga cables with silver soldered lugs. My cart was fresh off a 3yr lease at a golf course in Arizona where the air is dry, while your 2008 PDS is going on 6 years old and has been expose to the salty humid air of Florida. My guess is your cables are sicker now than mine were two years ago. New 4Ga cables ought to suffice, but I went with 2Ga because I'm an efficiency nut. |
03-06-2014, 11:40 AM | #30 | |
Gone Wild
Join Date: May 2012
Location: S. Fl
Posts: 237
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Re: 36 Volt to 48 Volt conversion- battery cable lengths?
Quote:
Thanks! |
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