1997 Club car DS 48V

zimmean

Ok I bought a 1997 club car ds 48c. Cheep batteries were shot. I replaced the batteries. Everything worked good cart drove fine. I followed an online article on how to upgrade the stock gray controller to 500a by adding transistors and resistors. I put a 2 gauge cable kit in everything worked fine again. I replaced the motor with high torgue motor and 400A solioid and Heavy duty F/R switch. The cart flew and worked fine. I started to put the body on and I arced the string of batteries. Now the cart will not run. The cart tries to go and the solinoid engages the motor tries to run but it just sort of shakes. I tested the batteries still 50v, the Solinoid, resistor and diode are fine and tested fine. The battery charger seems to function. I completed a OBC reset. I tested the 5k to 0k throttle circuit and it fine. I have even replaced the motor with the old stock motor hoping to find something. Nothing seems to work. Did I fry the OBC or the controller? I tried to bypass the OBC and the cart still doesn't run. Does anyone have any ideas?

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BGW

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zimmean

Tested the batteries individually and found one is toast. Reads high voltage but under load it has no power.

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zimmean

Must be battery shutter from what I read on other posts.

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Aflyer

I suspect your batteries are under warranty, or should I say I hope they are.

zimmean

Yeah I'm am hoping this fixes it and it's not the OBC or Controller.

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Golferdave

What battery type?

zimmean

They are UPS batteries from a Telcom application. Replaced the battery and cart work fine again.

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Sergio

If those are Gel batteries, you may need to get a few backups...

The OBC, or any other charger designed for FLA (Flooded Lead Acid), will destroy those batteries pretty quick.

FLA batteries are designed so the charging voltage promotes a strong Gassing effect that helps re-mix the electrolyte and avoid stratification.

If the Gel batteries experience this violent gassing, the Gelled electrolyte will develop voids like Swiss cheese.

You can also invest in a new charger that has a Gel battery specific charging algorithm.

zimmean

Thanks for the heads up

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