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Unread 09-02-2014, 08:31 PM   #1
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Default My 2001 DS won't stop charging

I have a 2001 48v Regen DS with 6x8v batteries. I have always left it with the Club Car charger switched on when not in use and all worked fine until recently. My problem is that, instead of turning itself off once the batteries are fully charged, the charger continues charging for ever at about 4 amps. The orange battery warning light on the dash panel also lights up for about 90% of the time when this happens and also comes on again for a few seconds when I unplug the charger from the charging socket. My guess is that the OBC is the problem. I have tried to reset the OBC following the instructions on this forum but when I get to the stage where you push the accelerator pedal down with the battery negative wire disconnected, the tow/run switch on, the rocker switch on reverse and the key switch on, I get no sound from the reverse buzzer. The batteries all hold 8.5 volts when charged and have decent specific gravity. I am unplugging the charger to stop the batteries from overcharging and the buggy gets me round the golf course with no problems whatsoever. Before paying big money for a new OBC, is there any way I can reset it other than the method on this forum? Would disconnecting it from the buggy cause it to reset? Or might it be the charger itself that is causing the problem?
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Unread 09-02-2014, 09:23 PM   #2
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Default Re: My 2001 DS won't stop charging

Not sure but it sounds like you are close to needing batteries. That light comes on when the obc thinks the batteries are not fully charged.
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Unread 09-03-2014, 04:14 PM   #3
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Default Re: My 2001 DS won't stop charging

Check your on-charge voltage when the amps get down to 4a. You should have 59-63 volts. That is when the charger should switch off. If its much lower than that your batteries are not accepting a full charge.
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Unread 09-09-2014, 09:15 AM   #4
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Default Re: My 2001 DS won't stop charging

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Originally Posted by Golfdog View Post
Check your on-charge voltage when the amps get down to 4a. You should have 59-63 volts. That is when the charger should switch off. If its much lower than that your batteries are not accepting a full charge.
Thanks for your reply. My on-charge voltage goes much higher than the range you mention. At 4 to 5 amps, the voltage climbs steadily from about 59 volts up to about 65 volts, which is when the orange warning light starts coming on. By that time the batteries are getting very hot and pushing out loads of fumes, so I switch the charger off now, as I know the batteries will keep on charging if I don't. The batteries are Club Car branded and made by Crown. I can't find a date of manufacture on them but the guy I bought the buggy from said they were about 2 years old. They have the single-piece swivel cell filler covers rather than individual plugs for each cell, if that helps to estimate the age of the batteries. My real question is whether it is the OBC or the Powerdrive charger that is the more likely faulty component. The charger responds to the OBC in the early stages of the charge, starting at about 12 amps and gradually dropping down to 5 or 4 amps, but that's where it stays and just keeps on charging for ever.
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Unread 09-09-2014, 01:10 PM   #5
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Default Re: My 2001 DS won't stop charging

A 48 volt pack can get as high as 67 volts before the charger turns off, when you say it charges for ever, what is for ever?/hours? It can take 16 hours to charge the battery pack
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Unread 09-09-2014, 01:30 PM   #6
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Default Re: My 2001 DS won't stop charging

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Originally Posted by rib33024 View Post
A 48 volt pack can get as high as 67 volts before the charger turns off, when you say it charges for ever, what is for ever?/hours? It can take 16 hours to charge the battery pack
It is still charging after more than 24 hours. I just don't let it run that long any more as the battery fillers are oozing acid and the batteries are really hot. I have just read on another thread that the K9 stickers on the batteries mean that they were made in November 2009, so maybe they are on their way out. I'll run an under-load voltage test next time I take the buggy out. Any idea of what kind of voltage drop accelerating from a standstill would indicate a problem?
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Unread 09-09-2014, 01:30 PM   #7
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Default Re: My 2001 DS won't stop charging

The only thing I would add is that "pack" is the keyword here.
Next time the pack gets up to 64+v, set your multi meter to the 20v scale and measure each individual battery. If you have one or more batteries considerably below the 'average' voltage (pack voltage/# of batteries), that could be the reason.
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Unread 09-09-2014, 01:43 PM   #8
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Default Re: My 2001 DS won't stop charging

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Originally Posted by Sergio View Post
The only thing I would add is that "pack" is the keyword here.
Next time the pack gets up to 64+v, set your multi meter to the 20v scale and measure each individual battery. If you have one or more batteries considerably below the 'average' voltage (pack voltage/# of batteries), that could be the reason.
Thanks. I'll give that a try later. I'm in England so it's evening time now and I might not get out to the buggy again before tomorrow. I'll post my findings, whatever.
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Unread 09-09-2014, 03:56 PM   #9
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Default Re: My 2001 DS won't stop charging

Okay, Sergio, I have the following on-charge readings from my multimeter:

Total pack 64.4 volts
Battery 1 (+) 10.53 volts
Battery 2 10.90 volts
Battery 3 10.67 volts
Battery 4 10.67 volts
Battery 5 10.95 volts
Battery 6 (-) 10.59 volts

The individual battery voltages only add up to 64.31 volts, so I seem to have lost 0.09 volts somewhere along the way! Do you see anything significant in these figures?

I have unplugged the charger as I don't want to risk leaving it on overnight. I shall check the off-charge voltages tomorrow morning, 15 hours after ending the charge.
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Unread 09-09-2014, 04:08 PM   #10
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Default Re: My 2001 DS won't stop charging

I would now suspect the OBC is faulty as it should have shut off the charger after 16hrs. If you can get access to another cart with a known good OBC, plug in your charger and see if it switches the charger off.
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