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Unread 02-05-2011, 09:38 PM   #1
Not Yet Wild
 
Join Date: Mar 2009
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Default Problem charging new 48V system

I hope you guys might can offer some advice. I have a 2001 club car DS. I found out it came stock with a 48V motor and controller and only needed to add the batteries to make it 48V and use all the power. I took it to a local repair place where they wired in the two used 6V batteries i purchased.

Problem I'm having is when I plug in my 48v charger it doesn't seem to charge the two additional batteries. I thought perhaps they were more drained than the others so I disconnected them and charged them full separately and then plugged everything back up. The original six batteries bubble away, but nothing on the last two.

Any ideas? I think everything is wired correctly as I paid the shop to do so but really not 100% sure.
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Unread 02-05-2011, 09:45 PM   #2
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Default Re: Problem charging new 48V system

So you're now running 8 - 6 volt batteries? Neat.

I would double check and make sure they are all 6 volt batteries. You may or may not already know this but you can count the water caps on a battery and multiply by 2 to get the battery voltage.

My first guess would be is that when the two batteries were added, the black ground that goes through the OBC wasn't moved to the last battery in the circuit. It depends on where in the battery circuit the two new batteries were added.

Also, verify that the two additional batteries aren't getting charged by checking them with a multimeter.

A quick picture would help verify that.

I'm sure one of the more experienced guys on here could verify what I've suggested.

Thanks,

Doug
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Unread 02-05-2011, 10:42 PM   #3
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Default Re: Problem charging new 48V system

All 8 batteries are wired in series beginning with the neg of batt 1 and ending with the + on batt 8.

In addition there are the following connections:
1. Batt 1 + is connected to the solenoid -- red wire in 1st pic
2. Batt 1 + is also connected tothe rear of the charger plug -- red wire in 2nd pic
2. Batt 6 neg is connected to the rear of the charger plug in (I'm wondering if this is my issue) -- black wire in 2nd pic
3. Batt 8 neg is connected to the controller -- black wire in 3rd pic

I don't really see anything from batteries to the OBC. See 4th pic


http://i872.photobucket.com/albums/a...9/100_1043.jpg
http://i872.photobucket.com/albums/a...9/100_1043.jpg
http://i872.photobucket.com/albums/a...9/100_1040.jpg
http://i872.photobucket.com/albums/a...9/100_1044.jpg
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Unread 02-05-2011, 10:55 PM   #4
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Default Re: Problem charging new 48V system

This is front of OBC. does this cover come off??

http://i872.photobucket.com/albums/a...9/100_1045.jpg
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Unread 02-05-2011, 11:22 PM   #5
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Default Re: Problem charging new 48V system

It appears that the charging system has been modified from the original setup. Your current setup is trying to bypass the OBC. Is that your intention or is that how it always was configured?

With a normal Club Car charger, the negative from the last battery (battery #8 in your case) in the series goes through that hole in the OBC to the controller (Yes, it must go through that hole). The negative from the back of the charging receptacle goes to the thicker black wire from the OBC (it's usually in the same wire wrap as the gray wire between the receptacle and the OBC).

It's hard to tell from the picture but I do see a black wire right behind the receptacle that isn't connected to anything (it's a skinnier gauge than a battery cable but thicker than all the others on the OBC) . Does that lead back to the OBC?

There are wiring diagrams in the sticky threads at the top of this forum. I would find the correct diagram for your year/model and verify the connections.

Do you know if it did go through the OBC before the local shop connected your two additional batteries? The black wire from the receptacle looks newer, like it was recently changed/added.

Out of curiosity, did you put the two additional batteries in the bagwell?

Thanks,

Doug
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Unread 02-06-2011, 08:54 AM   #6
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Default Re: Problem charging new 48V system

The shop we took it to did all the changes. I had no idea so that's what I paid them for! I may call them to see what the owner says. At a minimum I hope he will give me the extra cables I need. I see on the 48V diagram that it looked like it was going through the "hole". What does that do? I think that's what got missed. The way mine is wired is more like the 36V system (the last orig battery going ot the charger plug). I'll check the black wire from teh receptacle to the controller you mention.

Yes, the last two batteries are in the bag well. That's the plan for now until we need new batteries and then will go to 8V ones. My first 6 were pretty new.
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Unread 02-06-2011, 09:21 AM   #7
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Default Re: Problem charging new 48V system

I've stolen this from another thread:

"It's exactly a DC Current clamp-on ammeter (without, of course, the clamp-on function), that keeps track of amp-hours drawn from the battery when operating, and (usually) shuts the charger off after 110%(?) of that energy has been returned to the batteries."

I had a friend of mine with almost the same exact cart as yours upgrade to 4 gauge cables. He didn't run the negative through the OBC because the cable was already crimped and he couldn't run it through the OBC. A lot of people look at it and simply think it's just a convenient way to run the cable, not realizing that it's actually needed to be able to properly charge the batteries.

Also, I have found that sometimes, when I put new batteries in a cart, a reset of the OBC may be needed. It's not always true but it is sometimes the case.

BTW, I am not an authorized Club Car tech and do not have formal training to repair Club Car carts. Like many people on these forums, I have just read a lot of the topics and have worked on quite a few over the past few years. Guys like OldMec and Scottyb are much more knowledgeable than I am.

If you aren't comfortable with doing the work yourself, I would definitely have an authorized Club Car shop look at it. Although, we have seen plenty of shops improperly diagnose or wire up carts. :)

You should get a nice long run time on a charge with 8 x 6 volt batteries.

Good luck!

Doug
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Unread 02-06-2011, 10:02 AM   #8
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Default Re: Problem charging new 48V system

Take your voltmeter and measure the voltage at the charger receptacle. This way you can see way you can see how many batteries the charger is wired up to. I suspect the charger is only seeing 6 of the batteries. If you are using a Club Car charger you will need to have the OBC in the circuit. It looks like there is no cable running thru it now, so it will not be able to control the charger as it should. IF your charger is jumpered to run whenever plugged in you will have to fix that when you correct the cabling. Curious if the charger is Club Car & if it shuts off?
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Unread 02-06-2011, 11:09 AM   #9
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Default Re: Problem charging new 48V system

Basic ? ,
U never mentioned it but did it come with a 36 Volt Charger or 48 Volt Charger ?
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Unread 02-06-2011, 11:42 AM   #10
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Default Re: Problem charging new 48V system

The charger is a 48V club car charger and, no, it never shuts off. The first 6 battereis bubble but the new 2 don't at all and I knwo they are all fully charged as we did them separately. I think we are missing the connection "through" the OCB. what does that do? It looks like a pass through of a insulated wire??? I also think the wire from the charging receptacl to the 6th battery is wrong. Seems like that'd need ot be on the last battery in the series or not at all.

The cart came as 36V battery wiring w/ a 36V charger. worked fine then. We have hence taken it to have the new batteries added fo 48V and bought a used 48V charger. We still have the 36V charger unti lnext week.
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