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Old 11-23-2017, 06:40 AM   #1
FreshFromFL
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Default Dpi charger-not turning off

So I was seeming to have issues with my batteries, they seemed to run down after just a couple miles, maybe 18 month old batteries. I checked the water in them and they were low, after being at a normal level every other time I’ve checked them. I’d check monthly in the summer, and every couple months in the winter when we weren’t using the cart as much.

I thought it was strange that they would run down all of a sudden, some cells had almost an inch of exposed plates. But after refilling, I can’t get the charger to fully charge the batteries and shut off.

I took individual readings on my (7) 6v’s with a date stamp of dec 15. Readings were at:

6.3
6.42
6.29
6.25
6.27
6.35
6.28
Total pack reading of 44.17

When I plug in the charger, I get an instant 44.85, climbing to 49.67 within a few minutes, 51.57 within an hour and 50.58 after about 12 hrs on charge. You can really hear the water boiling in there after 12 hrs, and this scares me a bit. Sounds like rapidly boiling pasta. Is this boiling sound why they are gassing and losing water? Is my charger overcharging? Or not going into a finishing mode?

I’ve even tried to hook up another charger that runs 6v/12v at 5a and charge each battery individually. After that said they hit 100%, I plugged In The dpi and it still ran without finishing.

Are my batteries damaged from having the plates exposed for that little while, and aren’t capable of a full charge? Is my charger not kicking off and overcharging, damaging the batteries further? Any advice is greatly appreciated


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Old 11-23-2017, 09:20 AM   #2
scottyb
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Default Re: Dpi charger-not turning off

Batteries let off hydrogen gas when heavily charging. It does sound like boiling as the gas bubbles form and release from the bottom of the cells. This only happens during the charger's 1st cycle called bulk rate charge (maximum output).
There are 3 stages to the average charger algorithm, 5 stages in a DPI. The amperage decreases in each sequential stage.

One of 2 things is happening.
1. the batteries are damaged and cannot accept/hold the amperage being put in and this is keeping the charger from moving to the next phase and ultimately finishing the charge cycles.
2. The charger is malfunctioning and not reducing the output (going to the next phase) as it should.

You stated 50.58 max on charge voltage. That is 2.40 volts per cell (VPC). This may be slightly under the DPI requirement. The 44.17v pack reading clearly shows the pack holding just 90% capacity. I'm leaning towards damaged batteries.
It would be good if you could find another cart to try the charger on.
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Old 11-23-2017, 09:38 AM   #3
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Default Re: Dpi charger-not turning off

The boiling sound hasn’t been this intense in the past. Do these numbers seem normal? Am I risking further damaging the batteries by letting it run like this? How long should it stay in the first cycle? It’s been on this cycle for about 17-18 hours now

I don’t have another cart to test...


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Old 11-23-2017, 09:40 AM   #4
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Default Re: Dpi charger-not turning off

I would turn the charger off and run the cart a few miles. Check the water levels again and try recharging. The charge cycle should be done in 5-8 hours then, with the bulk rate charge lasting no more than 1 hour.
Cycling a few times like this may get them fully active again. If not the damage is done.
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Old 11-23-2017, 09:47 AM   #5
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Default Re: Dpi charger-not turning off

I’ll give that a shot as soon as this clears up

I have tried to run the cart after a charge like this then recharge, but I always worry that the charger is frying the batteries and shut the charge down after 3-4 hours of hearing the boiling.

Any idea why the cells started losing water so rapidly after normal use and results for over a year?


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Old 11-23-2017, 12:58 PM   #6
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Default Re: Dpi charger-not turning off

I'm sure Trojan (or whoever built your batteries) doesn't consider exposed plates "normal use". Also, I may have missed it, but did you always use distilled water? There are a few compounds that are lethal to batteries in low concentration (we're talking 5 PPM).
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Old 11-23-2017, 07:19 PM   #7
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Default Re: Dpi charger-not turning off

They’re crowns. Always used distilled water. I just think it’s weird going from just a slight fill in over a year, to needing over a gallon in a 3 week period.


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Old 11-23-2017, 07:53 PM   #8
WalterM6
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Default Re: Dpi charger-not turning off

My guess would be that you diluted your battery acid. You need to check the specific gravity of all the battery cells and replace the ones that are low. I don't trust float hydrometer so I recommend getting on of these.

https://smile.amazon.com/gp/product/...?ie=UTF8&psc=1
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Old 11-23-2017, 09:10 PM   #9
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Default Re: Dpi charger-not turning off

Quote:
Originally Posted by WalterM6 View Post
My guess would be that you diluted your battery acid. You need to check the specific gravity of all the battery cells and replace the ones that are low. I don't trust float hydrometer so I recommend getting on of these.

https://smile.amazon.com/gp/product/...?ie=UTF8&psc=1
Wow, that is a great price on a refractometer
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Old 11-24-2017, 08:57 AM   #10
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Default Re: Dpi charger-not turning off

Just ran the cart for a few miles, with a couple stops mixed in for less than 5 mins. Was reading a voltage of 28.55 under load, with a slow climb up to around 34 while under way. Cart started off feeling strong with quick acceleration, and slowly faded off until I felt like I was only getting 3/4 speed max and took a much longer time to get there


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