Beast Motors?

www3rd · 02-12-2009, 11:44 PM

wire held current post did not make it I had it in a bind tires were packed with mud expensive lesson spend all the money to make it right and still have weak point probably would have helped to use the fuse

Nate · 02-14-2009, 01:33 AM

If you don't mind I have a few other questions.

Did your post and cable all look good and clean?
What type of cable ends do you have, are they copper color or silver color?

I am tracing a problem that strikes modified electric carts without warning and you sound like you might be a candidate.

www3rd · 02-14-2009, 06:13 AM

yes they were clean and tight tin coated copper ends with t 105 batts

Nate · 02-15-2009, 11:26 PM

It sounds like your battery post had a thin oxide layer on it; I saw this on a cart that was having trouble in Louisiana. He was using ends that were uncoated copper but the lead oxide will still get you with tin or nickel plated ends as well. Put your charger on and monitor the current. When the current is 10 amps or a bit higher set your voltmeter on the mV setting. At ten amps you should see no more than 15mV across a connection.
How to read a connection? Put one meter lead on the lead post and the other meter lead on the tin connector that is touching the post you just put your first meter lead on. You are reading the resistance of the cable to lead post; this resistance is way to low for your meter to read on the ohm setting but can be high enough to cause damage.
Where did I get 15mV per 10 amps? That number I found to be very easy to beat and shows the potential of an issue. You can get below 5mV per 10 amps very easy.

Math:
15mV per 10 amps is .15 watts lost, doesn't sound like much and you probably won't have an issue with this. The gentleman whose cart I check was loosing 200mV at 10 amps which means at 500A his battery post was dissipating ~1000 watts of energy, more than 1 horse power and it melted.

scottyb · 02-16-2009, 09:04 AM

Nate, is this tribochemical decay a result of attaching dissimilar metals? I use bare copper ends on my custom cables? Is this something common?

Nate · 02-16-2009, 09:43 AM

I do believe it is the reaction you get from dissimilar metals touching each other. I also think it is more common than people realize, it didn't really start to show up until people started to boost the power of their carts to several times that of stock. Once a connection gets hot the oxidation process is accelerated.

scottyb · 02-16-2009, 10:07 AM

Does it occure at 48v? I have two carts I can check ....

Nate · 02-16-2009, 09:26 PM

It can occur at any voltage but you still need a fixed known current to check.

02-12-2009, 11:44 PM	#31
www3rd Not Yet Wild Join Date: Mar 2008 Location: south ms, Posts: 22	Re: Beast Motors? wire held current post did not make it I had it in a bind tires were packed with mud expensive lesson spend all the money to make it right and still have weak point probably would have helped to use the fuse

02-14-2009, 01:33 AM	#32
Nate Gone Wild Join Date: Dec 2006 Posts: 679	Re: Beast Motors? If you don't mind I have a few other questions. Did your post and cable all look good and clean? What type of cable ends do you have, are they copper color or silver color? I am tracing a problem that strikes modified electric carts without warning and you sound like you might be a candidate.
Nate Gone Wild Join Date: Dec 2006 Posts: 679

02-14-2009, 06:13 AM	#33
www3rd Not Yet Wild Join Date: Mar 2008 Location: south ms, Posts: 22	Re: Beast Motors? yes they were clean and tight tin coated copper ends with t 105 batts

02-15-2009, 11:26 PM	#34
Nate Gone Wild Join Date: Dec 2006 Posts: 679	Re: Beast Motors? It sounds like your battery post had a thin oxide layer on it; I saw this on a cart that was having trouble in Louisiana. He was using ends that were uncoated copper but the lead oxide will still get you with tin or nickel plated ends as well. Put your charger on and monitor the current. When the current is 10 amps or a bit higher set your voltmeter on the mV setting. At ten amps you should see no more than 15mV across a connection. How to read a connection? Put one meter lead on the lead post and the other meter lead on the tin connector that is touching the post you just put your first meter lead on. You are reading the resistance of the cable to lead post; this resistance is way to low for your meter to read on the ohm setting but can be high enough to cause damage. Where did I get 15mV per 10 amps? That number I found to be very easy to beat and shows the potential of an issue. You can get below 5mV per 10 amps very easy. Math: 15mV per 10 amps is .15 watts lost, doesn't sound like much and you probably won't have an issue with this. The gentleman whose cart I check was loosing 200mV at 10 amps which means at 500A his battery post was dissipating ~1000 watts of energy, more than 1 horse power and it melted.
Nate Gone Wild Join Date: Dec 2006 Posts: 679

02-16-2009, 09:04 AM	#35
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Beast Motors? Nate, is this tribochemical decay a result of attaching dissimilar metals? I use bare copper ends on my custom cables? Is this something common?

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02-16-2009, 09:43 AM	#36
Nate Gone Wild Join Date: Dec 2006 Posts: 679	Re: Beast Motors? I do believe it is the reaction you get from dissimilar metals touching each other. I also think it is more common than people realize, it didn't really start to show up until people started to boost the power of their carts to several times that of stock. Once a connection gets hot the oxidation process is accelerated.
Nate Gone Wild Join Date: Dec 2006 Posts: 679

02-16-2009, 10:07 AM	#37
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Beast Motors? Does it occure at 48v? I have two carts I can check ....

02-16-2009, 09:26 PM	#38
Nate Gone Wild Join Date: Dec 2006 Posts: 679	Re: Beast Motors? It can occur at any voltage but you still need a fixed known current to check.
Nate Gone Wild Join Date: Dec 2006 Posts: 679

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