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How To upgrade your electric golf cart to 72 volts!

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  • How To upgrade your electric golf cart to 72 volts!

    This is for 72 volts. These are list's of electrical components that will get you started on your way.
    The first list is if you want everything electric.
    { Pictures are for viewing only they may are may not be on a 72 volt cart}:lol:

    1. Controller that can handle 72 volts
    2. Contactor's for 72 volts, both main and F/R and Bypass if used
    3. Cables to handle the amps
    4. Motor to handle the voltage & amps

    Alltrax 72 volt controller: 7245 24-72V
    A big factor here is how long it will pull the amps. The 450amp is only good for 30 seconds and there is no rating from 30 seconds to 5 minutes so I can't say.
    5minutes is 350amps
    60 minutes is 200amps


    Note these are 400amp F/R contactor: Should be good enough for most carts



    Contact Ratings
    Contact Form 2Z
    Contact circuit Voltage and loading current(resistant) 84VDC Max 400A
    Contact Resistance 30mohm Max.
    20+-5C cold state max motion voltage(VDC) Pick-up <=70% of rated voltage
    Drop-out 5%-30% of rated voltage
    Mechanical life(Min.) 100,000 Ops
    Electrical life(Min.) 50,000 Ops
    Coil Ratings
    Coil rated voltage 72VDC
    Max coil current under the rated voltage 0.1A
    With 20+-5C cold state starting coil max current

    Specification
    Insulation Resistance 100Mohm Min.
    Dielectric strength Between Contacts 2000VAC.
    Between coil and contacts 1500VAC.
    Environment temperature and attitude -40C-+85C; 0-20000m
    Max relative humidity 98%
    The shocking of fixed point 1 Frequency(11Z) 10-200
    Acceleration(g) <3.5
    Shocking Speed(time/min.) 60-100
    Acceleration(g) 4
    Constant acceleration 8
    Operation regulation Continue
    Installation direction Random


    72 volt 400 amp main contactor:

    Contact Ratings
    Contact Form 1H
    Contact circuit Voltage and loading current(resistant) 84VDC Max 400A
    Contact Resistance 30mohm Max.
    20+-5C cold state max motion voltage(VDC) Pick-up <=70% of rated voltage
    Drop-out 5%-30% of rated voltage
    Machanical life(Min.) 100,000 Ops
    Electrical life(Min.) 50,000 Ops
    Coil Ratings
    Coil rated voltage 24V,36V,48V,72V,84 VDC
    Max coil current under the rated voltage 0.1A
    With 20+-5C cold state starting coil max current

    Specification
    Insulation Resistance 100Mohm Min.
    Dielectric strength Between Contacts 2000VAC.
    Between coil and contacts 1500VAC.
    Environment temperature and attitude -40C - +85C; 0-20000m
    Max relative humidity 98%
    The shocking of fixed point 1 Frequency(11Z) 10-200
    Acceleration(g) <3.5
    Shocking Speed(time/min.) 60-100
    Acceleration(g) 4
    Constant acceleration 8
    Operation regulation Continue
    Installation direction Random

    I can't strees how much your cables and all the wiring must be in top shape for a high voltage cart. Everything needs to be check often and kept in very good shape. Cables should be crimped and heat shrinked at the least.





    Motors can be ran at higher voltages as we all know but if your building a high voltage & amp cart make sure the motor will handle it.


    If you want to go the old mechanical way to go from Forward to Reverse make sure you upgrade everything in the Mechanical F/R handle.
    Stock and mine:
    As far a s I know there is no upgrade springs are copper contacts for the F/R switch so replace the old ones with new parts. They are cheap.[/b]



    Stock and mine:


    Completely rebuilt with everything new.


    Hope this helps some of you thinking about going 72 volts. If I can help just ask.
    Attached Files
    Updated by Michael Eddie; January 11, 2012, 08:02 PM. Reason: Made into article
    sigpic
    I'm here to help!
    There is no substitute for Voltage!

  • #2
    nice guide!

    very, very few carts will pull anywhere near 350, or even 250 amps at cruising speeds. i think terry said his was pulling something like 100A while cruising and thats with a monster speed motor and high speeds gears. sustained current ratings aren't as big a deal as the marketing department would like for you to believe. what you need to watch for is heat. and if dissipating the heat becomes a problem... add a fan or two.
    -sj

    Comment


    • #3
      Yeah Baby... Now you're talkin!

      Not a big amperage demand on this mod, the axles, springs and shackles will be the stressed parts.

      Reminds me of my old hot rod days, keep upping the mods until things start to break then beef up the broken parts.
      Updated by dougmcp; January 10, 2012, 08:25 PM.

      Comment


      • #4
        Posted earlier by sonicj View Post
        nice guide!

        very, very few carts will pull anywhere near 350, or even 250 amps at cruising speeds. i think terry said his was pulling something like 100A while cruising and thats with a monster speed motor and high speeds gears. sustained current ratings aren't as big a deal as the marketing department would like for you to believe. what you need to watch for is heat. and if dissipating the heat becomes a problem... add a fan or two.
        -sj
        That's why I added that. They want you to believe a 700 amp controller is better than a 400 amp. In certain cases it may be but unless your drag racing are climbing Mt Everst everyday you could get by with a 400 amp controller.
        Yes a little more amps is ok with larger wheels but you don't need 700 amps to go 30 MPH. You do need it if your cart has those big tires, if up against a wall are very steep hill. Nothing a running start wouldn't fix.
        The heat is a good point and that's why I said all components must be checked and in top condition always not just after the build. From then on you must keep everything right.
        Terry was going for speed more than torque I bet he could use a 300 amp alltrax and do what he is right now. He would be close if not the same. The weight of his cart to get moving isn't that bad I would think. Once moving it could run on 100 are less depending on the terrain.
        sigpic
        I'm here to help!
        There is no substitute for Voltage!

        Comment


        • #5
          Here are some links for high amp stuff.

          http://www.cloudelectric.com/default.asp

          http://www.evdrives.com/contactors_solenoids.html

          http://www.vendio.com/stores/rcfuthe...c/lid=14031219

          http://www.batterypowersystems.co.uk...rsContacts.pdf
          sigpic
          I'm here to help!
          There is no substitute for Voltage!

          Comment


          • #6
            Nice article Andy! Moved to the articles section, thanks for sharing!
            Regards,

            Comment

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