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Unread 11-07-2012, 07:39 AM   #1
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Default batteries overheating during charge

I'm reposting this as the last post was on the wrong thread. New to this. I have a club car XRT810, batteries are about 2 years old and I keep terminals clean and water in the batteries. I have a powerdrive charger 3 about a year old. When I charge the batteries the amps go to 15 and don't drop. Although after 4 hours I unplug the charger even though not fully charged because the batteries are very hot to touch and the water is boiling inside. Is this normal that the batteries get that hot during a charge?? I'm worried about over charging. Why would the amp meter not start to drop after 4 hours?? Also when driving the battery indicator drops rapidly and will not go back to show full even after batteries are charged. If i disconnect and reconnect then the indicator goes to full. could that just be a faulty indicator. Also the yellow battery light has been going on and off every few minutes while driving.
Other parts that have been replaced in the last 2 years are, charging receptacle, solenoid & battery cables.
Anyone have any ideas? I've been running tests on the OBC as per manual and haven't found a problem with it yet. Also did the OBC reset.
Don't know where to go from here and need help.
Also when going uphill I feel a kick and it powers down, goes really slow then slowly picks up a little speed, but not much. Is this related? Or another issue? This golf cart is being used on steep inclines and rough roads.
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Unread 11-07-2012, 08:41 AM   #2
The Last Moja Morani
 
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Default Re: batteries overheating during charge

its normal for the batteries to boil as long as they arn,t boiling water all over the place and yes they get hot also......can,t say how hot because every set reacts different.....it could be the fact your unplugging it at 4 hours as it can and will sometimes take up to 16 hours and then charger will shut off on its own.......its made to time out at 16 hours.............this is what you need to do plug charger in and leave it alone, your gonna have to let the batteries charge fully and then things will change....it may take 8 or more hours before amp meter starts dropping off 15 amps again normal.......its very important you leave the charger do its job cause what your doing now is killing the batteries...........thats the reason your lights coming on your gage isn,t working right......your batteries are starving, i,m not sure how long you have been doing this but it might take a full 16 hours and charger will shut off and you,ll have to start a 2nd time which at that point you,ll more then likely get a full charge in them.......you,ll notice the difference real quick........................
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Unread 11-07-2012, 09:46 AM   #3
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Default Re: batteries overheating during charge

Something might be wrong with the charger or the batteries. I haven't seen a charge cycle yet that stayed in stage 1 for 4 hours! Usually stage 1 in done within the first hour. After that the charge rate should drop off significantly.
Load test you batteries first. Then check your charger on another cart with known good batteries second.
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Unread 11-07-2012, 10:57 AM   #4
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Default Re: batteries overheating during charge

Quote:
Originally Posted by scottyb View Post
Something might be wrong with the charger or the batteries. I haven't seen a charge cycle yet that stayed in stage 1 for 4 hours! Usually stage 1 in done within the first hour. After that the charge rate should drop off significantly.
Load test you batteries first. Then check your charger on another cart with known good batteries second.
scotty are you funnin ?? i see it all the time when someone keeps pulling the plug on the charger i have seen them sit there for 6 even 8 hours before amp meter starts dropping and even then its a real real slow drop to a certain point.......you have to have run into this before...........granted there could be something going on but the only way to know for sure it let the charger do its job as long as its not boiling water all over the place and you can,t fray an egg on the battery if you pull the plug on it several times at 4 hours its just gonna take longer.................................
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Unread 11-07-2012, 11:05 AM   #5
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Default Re: batteries overheating during charge

I still think 4 hours on stage 1 is too long and might indicate a battery pack that has been drawn down too low or a battery that is not responding or a charger board that is not right?
I have to charge up a few carts I will try to watch and time the stage 1 cycle.
If you could do the same on your cart?...
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Unread 11-07-2012, 12:14 PM   #6
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Default Re: batteries overheating during charge

Thanks for your replies. But I pulled the plug before I read them.
But this is why. I started the charger at 5am this morning. At 7am the full bank read 52.2 charger on. at 11am it read 51.9. Amp meter did not drop below 14amps. I got impatient after 6.5 hours and pulled the plug. The reading then was 47.9.
I then disconnected all the batteries and tested each individual.
battery 1 - 10.54
battery 2 - 12.52
battery 3 - 12.43
battery 4 - 12.53

I now am charging each battery individual with an external charger. Starting with battery 1. Once they are charged (if they do) I'll do a load test.

Does this sound like the right thing to do
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Unread 11-07-2012, 12:22 PM   #7
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Default Re: batteries overheating during charge

One other thing I may do is change the connection from the red wire that goes to the charger receptacle. It looks a little compromised. Anyone know if that could be a problem too?
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Unread 11-07-2012, 09:12 PM   #8
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Default Re: batteries overheating during charge

If the receptacle contacts are bad they can be intermittent and get hot... but just judging by the high voltage readings you are getting I'm going to guess you are getting the juice to the pack okay.

As promised, I did watch one cart charge today.... I have a new set of batteries, this will be their 6th charge cycle so they are not yet broke in. We know that new batteries and old batteries can take a long time to charge.

Lester 25 amp charger.... Pack at 75%

Plugged the charger in and the ammeter indicated it immediately went to 25 amps.
After 1 minute it settled in at 22 amps, this is stage 1 of the charge algorithm. Stage 1 is the bulk recharging phase I suggested should not take more than 1 hour on a healthy pack. This is when the heavy amperage is replenished across the pack. (80% of the charge is done in this phase and this is why opportunity charges are effective)
After 15 minutes bulk charge had backed down to 18 amps.
After 30 minutes bulk rate had reduced to 16 amps
At 50 minutes the ammeter dropped to 13 amps = Stage 2. It's called the absorption stage or very loosely termed an equalization stage. The batteries are venting at this stage ... As I bend over to write notes on the seat I get good wiff of acid vapors. I'm glad I'm outside.
At 60 minutes the ammeter reads 11 amps
At 90 minutes it's at 8 amps and dropping.
At 2 hours it's at 5 amps or officially stage 3 = the float stage.
At 3 hours the meter has settled in at 3 amps and holding ........ like forever........ 4 hours, no change. voltage in the pack has leveled off....
At 5 hours It shuts off.

I hope this helps
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Unread 11-07-2012, 10:01 PM   #9
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Default Re: batteries overheating during charge

Batt #1 may have a bad cell.
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Unread 11-08-2012, 11:29 AM   #10
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Default Re: batteries overheating during charge

Update. Started to charge battery #1 with external charger. Got it up to 11.8 before charger broke down. Old and has not been working well. Anyway decided to hook batteries back up and try with cart charger.
Much better although not 100%
Charger on pack reading started at 52.8. Two hours later 54.1, one hour after that charger clicked off and back on to keep charging. Left overnight to charge. This morning ran down and up steep hill and still holding a charge of 49.2.
Put the charger back on and after one hour amp meter was down to 12.
Two hours after that charger shut off.
End reading 49.9
I don't expect that to be 100% but working better and may get a few more months out of them.
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