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Unread 09-28-2019, 09:37 PM   #1
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Default PowerDrive 3 charger

Powerdrive 3 charger question.

When I bought my cart (98 DS 48 volt) it had old batteries (5 years old) I plugged in the charger and it turned on no problem started out at 15-16ish amps after several hours tapered off to 4-5 amps but never shut off. I could hear some bubbling and a bit of sulfur smell. I assumed batteries were at the end of their life cycle so I bought new batteries.

So I ran the cart probably 2-3 miles with new batteries and plugged in charger. It turns on and shows 15-16 amps and after about 30 to 60 minutes it just shuts off. Amps donít drop down it just shuts off. From what research Iíve done this isnít normal. Amps should taper off to 4-5 and eventually shut off when fully charged, correct?

Is it possible my batteries are charged completely in 30-60 minutes without amps dropping first? Seems odd with old batteries charger stayed on and now with new it shuts off that quickly?
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Unread 09-28-2019, 10:36 PM   #2
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Default Re: PowerDrive 3 charger help

Is the main negative battery cable still routed through the hole in the obc?
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Unread 09-29-2019, 01:45 AM   #3
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Default Re: PowerDrive 3 charger help

All be ****.. I made all of my own cables did them with 1/0 awg it wouldnít fit so I bypassed it.. I just installed the old 6 awg ground through the OBC and charger is functioning properly... thank you. Iím new to electric vehicles. Iíve been wrenching on my own cars as long as I can remember but that was no doubt a newbie rookie mistake.

So with that being the problem can I use my 1/0 awg ground with the 6 awg going through the OBC so the charger works but I still get the benefits of the 1/0 awg? Essentially run two ground wires?
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Unread 09-29-2019, 07:51 AM   #4
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Default Re: PowerDrive 3 charger help

That is not going to work either, there can only be one pack negative cable and it has to go through the OBC.

Build a stud out of 5/16" x 3 1/2" brass bolt and use two short 1ga cables, one on each side, to complete the path from battery post to Controller B-.

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Unread 09-29-2019, 07:57 AM   #5
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Default Re: PowerDrive 3 charger help

You only want (1) one negative cable. It needs to go through the OBC so that it can keep up with how much you have used out of your batteries. DO NOT drill the hole out, it is a sensor that measures the current. You can make a brass stud to go through the OBC. use double nuts to keep it from crushing the OBC you want some play on each side, put tape on the part that goes through the hole. You will have a short cable on each side. 5/16 is the stud size.
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Unread 09-29-2019, 08:00 AM   #6
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Default Re: PowerDrive 3 charger help

I type slow and Sergio said the same thing with fewer words,
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Unread 09-29-2019, 08:27 AM   #7
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Default Re: PowerDrive 3 charger help

I am glad you mentioned wrapping a few turns of electrical tape on the center of the stud (I had not done that yet on the picture), it helps preventing the sharp stud threads from being abrasive to the protecting coating inside the hole.
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Unread 09-30-2019, 02:14 AM   #8
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Default Re: PowerDrive 3 charger

You guys are awesome thank you. Building my stud kit tomorrow ��
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