8V batteries won't fully charge

im4rmk

I have a 2002 club car and a powerlink2 model 22110 charger. I have 6-8v batteries. 4 batteries are less than 2 years old and 2 are less than a month old. When I plug in the charger, it goes all the way to the right. After going back to "0" for its test, it always shoots back to 15+ (far right). The needle is never in any position other than the far right or off. After it shuts off, my batteries all show a charge of about 7.5 volts. I can barely make it to my mailbox and back before it runs out of juice. I have all brand new 2awg crimped cables. Hydrometer shows all cells in the red - not fully charged. I have no idea what is wrong or how to proceed. Any help would be greatly appreciated. Thank you. Amy

BGW

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Sergio

Make sure You did not change the charging system when installing the 2ga cables.

You can only have a single cable on the pack negative battery post and that cable must go through the OBC.

Also make sure the red wire from the back of the charger receptacle goes to the pack positive battery post.

im4rmk

The problem was actually occurring before I changed the cables. I was hoping that cables were the problem. They are installed correctly.

Sergio

How long does the charger run before turning OFF?

It sounds like the OBC cannot read the charging current, how did you get the 2ga cable trough the OBC?

im4rmk

It was a tight fit, but it went through without the terminal attached

scottyb

Use your voltmeter to verify the charger is really charging the batteries.
Check & note the battery pack. Plug in the charger and verify the pack voltage is rising.

im4rmk

It is charging - the pack voltage does rise. After reading some other information online, it sounds like it could be the rectifier. Is there a way for me to test that?

Sergio

If You loose one of the rectifiers there will not be enough voltage on the charger to cause the ammeter to go 15 amps.

After the initial - ON - wait a few seconds - OFF - ON again, how long does the charger run?

if less than 15 minutes and the current stays at 15 amps, the OBC hall effect sensor (where the cable goes through the OBC) has been damaged and it can no longer detect the current.

Try running the gray sense wire from the charger receptacle directly to pack negative.

That will force the charger to stay ON once you plug in IN.

Keep measuring the pack voltage and disconnect the charger once the pack reads 60v.

That old OBC should allow current on the 10ga cable even if it did not initiate the charge.

If that works, You need to get a smart charger to replace the OBC + powerdrive charger combination.

im4rmk

Thank you - I will test it out and let you know what happens.

im4rmk

Charger still shuts down prematurely. How do I test the rectifier?