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Old 01-28-2023, 06:53 PM   #1
rob_c28
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Default Voltage reducer setup issues

So I got the voltage reducer and Fuse Box and set it all up. Now I got some strange behavior.

I have a switch on the 48v + line so I can turn the reducer on and off. Well it seems like the switch is not function properly as it is not turning off the circuit when in the off position. Everything continues to work regardless of toggle position.


The setup I have…
Pack + going to switch then from switch to Voltage Reduce + input
Pack - going to Voltage reducer - input
Voltage reducer Output + to fuse Box +
Voltage reducer Output - to fuse Box -
Headlights going to positive and negative on fuse box

I should add there is a 25 fuse on the voltage reducer + input
I have a 15 fuse on the headlight positive (came pre installed)
And added a 15 fuse into the fuse box for the headlights

I check voltage at positive and Neg on the fuse Box and get 12.25v regardless of toggle switch position.

Could I be blowing the switch with the amount of power? This is the switch I purchased


Nilight 90012E Heavy Duty Rocker Toggle 15A 250V 20A 125V SPST 2Pin ON/Off Switch Metal Bat Waterproof Boot Cap Cover-5 Pack, 2 Years Warranty https://a.co/d/9CIEY4b
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Old 01-28-2023, 08:57 PM   #2
Volt_Ampere
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Default Re: Voltage reducer setup issues

Yes. Most reducers draw a big arc when you connect the 48V. This can weld the switch contacts.
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Old 01-28-2023, 09:01 PM   #3
rob_c28
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Default Re: Voltage reducer setup issues

Is there another switch you would recommend? Or should I do the hookups at the battery and then the last move plug the 2 pins in at the switch last?
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Old 01-28-2023, 09:45 PM   #4
Volt_Ampere
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Default Re: Voltage reducer setup issues

If your reducer is a 4 wire with no trigger wire, then you need to use a pretty beefy switch and maybe a capacitor to reduce the arcing when the connection is made. My two carts have 5 wire reducers with a trigger wire that disables it without arcing. But when I connect the 48V lead to the battery, I get a big arc which scared the crap out of me the first time I hooked it back up after working on the cart. I'm not sure that these 4 wire ones are intended to be switched. You could measure the current going to the reducer with your 12V stuff shut off and if it's very small, then I would just leave it hooked up without a switch.
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Old 01-29-2023, 06:43 AM   #5
meimk
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Default Re: Voltage reducer setup issues

Some have used a relay / solenoid to take that current spike.
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Old 01-29-2023, 06:59 AM   #6
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Default Re: Voltage reducer setup issues

Quote:
Originally Posted by meimk View Post
Some have used a relay / solenoid to take that current spike.
One with a resistor to suppress the arc would be best im thinking like what you have on the main solenoid. Maybe this is why some connect to that solenoid instead.
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Old 01-29-2023, 08:17 AM   #7
meimk
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Default Re: Voltage reducer setup issues

The only issue with the main solenoid is that it is normally only engaged when you on are the go pedal and moving. Having your lights & sound system go dead every time you come to a stop is less than ideal.

Last edited by meimk; 01-29-2023 at 08:19 AM.. Reason: Typo
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Old 01-29-2023, 09:17 AM   #8
augiedoggy
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Default Re: Voltage reducer setup issues

Quote:
Originally Posted by meimk View Post
The only issue with the main solenoid is that it is normally only engaged when you on are the go pedal and moving. Having your lights & sound system go dead every time you come to a stop is less than ideal.
oh I agree that's how some carts solenoids work. I've been told some keep the solenoid engaged when the key is on but I don't know how true that is.

But if you have a stereo system you want a reducer that's either always on or one that has 12v memory power that's always on anyway right? Otherwise it will default to 88.7 with no memory presets or sound settings every time you turn it back on.

I bought the 48v relay for mine but then I scored an open box 30a pro chaser reducer that has the key switch wire so I plan to use it instead.
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Old 01-30-2023, 09:01 PM   #9
Cobra,1
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Default Re: Voltage reducer setup issues

I used a 48 volt relay connected to solenoid so when key on it closes relay supplying 48 volts to 12 volt reducer this power to fuse block and 12 volt accessories. This way amp draw is not running thru toggle switch as relay acts as switch

A toggle switch would only be needed to turn relay on or off.
Or use carts solenoid to turn relay on or off
I used carts solenoid so key on, relay closed, sending power to convertor.
Hope I explained that correctly 😊
Electricians here can give better explanation of how relays work which I am not
one of 😊
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Old 02-01-2023, 05:49 PM   #10
donroger1
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Default Re: Voltage reducer setup issues

Quote:
Originally Posted by rob_c28 View Post
Is there another switch you would recommend? Or should I do the hookups at the battery and then the last move plug the 2 pins in at the switch last?
I used this "switch" to disconnect the converter supply.
https://www.amazon.com/AWBLIN-Discon...61&sr=8-1&th=1

I have a 12v solenoid on the output of the converter controlled by the key switch to "kill" the output as well.
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