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Old 04-08-2011, 07:40 PM   #1
BTCDC
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Default battery issues

I have a 07 PDS 36v with 06 batteries per the ground post, along with a Power Wise qe charger. this has no gauge just a light indicator (long green=<80% short green>80% solid 100%, red blink default code.

Heres my problem, from full charge i can take a 10 minute ride come back and plug it in for the night, it will blink green for days and finally turn red. at this point the batteries and wires are super hot. I was told by one of the local guys that I have a week battery in the pack and I need to equalize them. this is done by disconnecting them and take voltage reading on each. find the weak one and charge up to full. hook them back up and run for a while and charge as normal. well i disconnected and took volt readings and here is what I had; 6.32, 6.31, 6.37, 6.35, 6.31, 6.36. so none really seemed out of the box. so i left them disconnected for a day and rechecked at 6.09, 6.19, 6.24, 6.24, 6.15, 6.25.

didn't see the need to charge one battery seperate. I connected them back up and while making the last connection it has a pretty good draw due to the spark. so i flipped the run/tow to tow and no spark while making last connection. back to run and pretty good spark again.

so it is on charge again with a long green. oh all the batteries have water as required.

I tried the dionastic code check and no beeps.

what else can I check?
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Old 04-08-2011, 09:51 PM   #2
Andy4639
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Thumbs up Re: battery issues

6.09, 6.19, 6.24, 6.24, 6.15, 6.25.

The 6.09,6.15, 6.19 batteries are low. Compared to the pack. Good rule of thumb is no more than .04 off of any battery in the pack. So if the highest one is the 6.25 then the lowest shouldn't be lower that 6.21 anything lower is a low reading.
I know it sounds picky but it's how I do my math.
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Old 04-09-2011, 06:51 AM   #3
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Default Re: battery issues

I hooked them back together last night flipped it into TOW mode to eliminate extra draw, let them charge for 12 hours, still have a long green blink, < 80% charged and the batteries and wires were extremely hot, along with the batteries boiling. I unplugged it to allow everything to cool before continuing. Once this is done can I connect two batteries together and charge with a 12v charger due to the fact my car charger does not have a 6v setting.

And if I do charge all separate what is the reading suppose to be at fully charged per battery?

And should I jack it up and see what the volt per battery while under a load?
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Old 04-09-2011, 08:44 AM   #4
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Default Re: battery issues

A better option is to put the front tires against a wall, put the car in forward and depress the acc pedal slightly and check each battery's voltage then, this will simulate a full load similar to using a discharger (what we use). . . . the usual problem in trying to isolate certain batteries to replace is that in doing so you will simply have a problem with the next weakest link (battery[s]). Likely with batteries of that age, they are likely on or beyond their last leg, though.

Edit- Keep the voltmeter on each one long enough to see if the reading is dropping . . .
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Old 04-09-2011, 12:01 PM   #5
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Default Re: battery issues

Quote:
Originally Posted by Mark442 View Post
A better option is to put the front tires against a wall, put the car in forward and depress the acc pedal slightly and check each battery's voltage then, this will simulate a full load similar to using a discharger (what we use)
Sorry Mark442, I can't agree with this method of testing.
Don't do this with a PDS cart unless you have the money to replace the motor and controller.

Clip your leads to the battery (s) and take it for a drive. If the pack or any battery drops below 80%-85% of what you started with (30.5v/pack and 5.2v/battery) you have a bad battery or connection/cable.
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Old 04-09-2011, 12:19 PM   #6
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Default Re: battery issues

These readings will be right out of the whole right? so with the leads hooked up, take initial readings, and as soon as speed levels off that is when I take the running readings?
not after run time.

So just so I'm straight, if reading drops to 80%-85% of the pack as soon as I take off. Then connect to each individual battery and do the same check and the one that falls off is my bad one(s).
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Old 04-09-2011, 12:37 PM   #7
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Default Re: battery issues

Quote:
Originally Posted by dougmcp View Post
Sorry Mark442, I can't agree with this method of testing.
Don't do this with a PDS cart unless you have the money to replace the motor and controller.

Clip your leads to the battery (s) and take it for a drive. If the pack or any battery drops below 80%-85% of what you started with (30.5v/pack and 5.2v/battery) you have a bad battery or connection/cable.
Hi Doug,
Point taken and this certainly could cause harm if accelerated too vigorously . . . although we service some 1500 lease cars (about 35% electric PDS/65% gas) weekly and on rare occasions one of my techs will be in the field without a discharger (for reasons that have always eluded me - lol) and done this without issue . . . the key word I should have emphasized was *slightly*.

Our dischargers stop when the pack reaches a state of discharge at 31.47V.

Thanks for the input and very valid caution.
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Old 04-09-2011, 06:55 PM   #8
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Default Re: battery issues

so here are the results. intitial reading of pack was 39.02 running volts 35.5. individual battery
batt before/run
(1) 6.29/5.89
(2) 6.22/5.80
(3) 6.24/5.92
(4) 6/25/5.92
(5) 6.22/5.86
(6) 6.24/5.85
looks like they all drop below the desired level, so could it be one battery draging them down or
do I need to cut back to 1 meal a day and purchase a whole pack
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Old 04-09-2011, 07:34 PM   #9
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Default Re: battery issues

cut back to 1 meal a day, thats funny, TRUE but funny anyway. Good luck with your battery woes, I know it can be very frustrating.
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Old 04-09-2011, 08:27 PM   #10
Andy4639
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Question Re: battery issues

That is a bunch of drop for all 6 batteries. I would say it's time to cut back and buy a set of batteries.
When you checked the batteries did they drop then come right back or did they stay down. When you first hit the pedal a drop is normal to see but they should come right back up to the reading or very close to it.
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