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Unread 03-13-2018, 07:07 AM   #1
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Default Help! Charger won't shut off

I've read previous forums on this issue, but thought I'd get some more input. I have a 99 Club Car DS 48 Volt electric. In the fall I was having charging issues, the light on the dash would come in, and it didn't seem like the charger was running a full cycle before shutting off. I chalked it up to bad batteries. So the other day I put brand new Trojan T-875's in it. Voltage is at 50.3. The charger waits a few seconds, clicks on, then drops voltage for a second, then goes back up, I understand this is normal. The gauge on the charger reads 15 amps. Voltage climbs to 51.3 within 20 seconds or so. Here's where I get confused. The voltage continues to rise: and with in 2.5 hours, I get to 63.8V. Gauge on charger reads 3 amps. At this time, you can hear the batts bubbling and smell. Seems like a lot of voltage, and in fear of damaging brand new batts, I unplug the charger. Am I being the protective mother of my new battery babies, or do I have a problem with the OBC or charger?? Thoughts are appreciated. Thanks in advance. Casey
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Unread 03-13-2018, 07:13 AM   #2
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Default Re: Help! Charger won't shut off

Every thing you said sounds great, except unplugging the charger there at the end . That is the way the charger is suppose to work. Just let it go and it will turn off on its own.
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Unread 03-13-2018, 07:54 AM   #3
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Default Re: Help! Charger won't shut off

You need a new charger. The charger shouldn't go higher than 59.2v. Your charger is running wide open. Get yourself a DPI charger.
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Unread 03-13-2018, 07:58 AM   #4
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Default Re: Help! Charger won't shut off

You charger is just fine. It is working correctly.
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Unread 03-13-2018, 08:20 AM   #5
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Default Re: Help! Charger won't shut off

Agreed - charger is fine so far. Old chargers cut off much lower than we see chargers cutting off at today. I have a newish Lester that cuts off at 65v. I was concerned with the high level so I contacted Trojan Battery techs who assured me that level was fine. The bubbling sound is gas bubbles being released - this is necessary for proper mixing of the heavy elements.
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Unread 03-13-2018, 08:29 AM   #6
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Default Re: Help! Charger won't shut off

The 3AH the charger is placing on the batteries will not cause any issues.

Under normal operating conditions (coulomb counting), the OBC voltage will not go that high and the current will not go down that low.

The OBC however uses a dV/dt algorithm after it has been reset and that mode does not use the OBC hall effect for charging.

You need to allow the OBC to finish its "baseline" charge so it can switch to the "energy out -> energy in" (coulomb counting) method.

As mentioned before, Do not interrupt the charging cycle.
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Unread 03-13-2018, 09:56 AM   #7
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Default Re: Help! Charger won't shut off

Alright, I'll let it charge. Thanks for all your input. Again, I was just concerned about the high volts, but sounds like that's ok. Thanks again.
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Unread 03-13-2018, 10:16 AM   #8
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Default Re: Help! Charger won't shut off

Quote:
Originally Posted by cjhevlin View Post
I've read previous forums on this issue, but thought I'd get some more input. I have a 99 Club Car DS 48 Volt electric. In the fall I was having charging issues, the light on the dash would come in, and it didn't seem like the charger was running a full cycle before shutting off. I chalked it up to bad batteries. So the other day I put brand new Trojan T-875's in it. Voltage is at 50.3. The charger waits a few seconds, clicks on, then drops voltage for a second, then goes back up, I understand this is normal. The gauge on the charger reads 15 amps. Voltage climbs to 51.3 within 20 seconds or so. Here's where I get confused. The voltage continues to rise: and with in 2.5 hours, I get to 63.8V. Gauge on charger reads 3 amps. At this time, you can hear the batts bubbling and smell. Seems like a lot of voltage, and in fear of damaging brand new batts, I unplug the charger. Am I being the protective mother of my new battery babies, or do I have a problem with the OBC or charger?? Thoughts are appreciated. Thanks in advance. Casey
Just like mrgolf and the others stated, that voltage is correct and is normal for your system and more so on a new set of batteries. This is an excerpt right out of the Power Drive manual under the charging section:

It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used. With IQ System, PowerDrive, PowerDrive Plus and Excel System vehicles, this is not necessary; the onboard computer controls and monitors the charge cycle. If any problem occurs during a charge cycle, the battery warning light, located above
the steering column in the center dash panel, will illuminate intermittently.
If the battery warning light is illuminated after a charge cycle, refer to the troubleshooting chart in the maintenance
and service manual appropriate for your battery charger. If you do not have this publication, contact
your Club Car representative. If the specified test procedures identify no problems, plug the DC cord into the
vehicle and let it charge until the charger shuts off automatically.
If a problem is found, correct it and then
charge the vehicle. Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts.
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Unread 03-13-2018, 11:59 AM   #9
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Default Re: Help! Charger won't shut off

Ok, just an update.. been charging for 1.5 hours....and I'm at 65 volts. Meter on the charger is still about 3 amps.
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Unread 03-13-2018, 12:12 PM   #10
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Default Re: Help! Charger won't shut off

It is probably getting ready to finish as 66v is about the maximum.

I am assuming that You never finished a complete charging cycle since the batteries were disconnected last time.
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