Charging System Troubleshooting

[Newt21]

Whole system was 53

[NoleFan4Ever]

Originally Posted by Newt21

Whole system was 53

Do it again for me and check the DC amperage. So far, it sounds ok. It may just be the bad batteries and that is looking more and more like the issue.

Post the voltage and the DC amps.

[Newt21]

How do I do that?

I was able to take the old battery back and trade it for a new one since it was under warranty, they only had one for now so I could only take the 5 volt one. So it is no longer in the equation. I still have the one that read as 7 volts.

[NoleFan4Ever]

The Voltage will be seen on your hand-held VOM across the main pack + & - posts. Then on the front of your Powerdrive you will see the DC Amperage. Do both of these as soon as you get it plugged in. And then come back an hour later and check them both again, then individually all six (6) batteries and post all of your results.

[Newt21]

After I installed the new battery (and before I saw your reply) I plugged in the charger, it clicked, and did the same as before (turned on, and progressively dropped to 5 amps). I left it charging and it cut itself off after a few hours. All individual batteries read 8v, the total system read 52 volts.

Should I unplug the charger, wait for a specified amount of time (how much if so), and then try to get the amperage?

Edit: I plugged in the charger again, the charger started around 10 amps and dropped after 2 seconds to 6 amps. The battery pack itself read 59 volts.

Edit 2: the charger cut itself off after about 12 minutes.

[NoleFan4Ever]

The charge voltage is right, the amperage is good if it sees the pack full. The cells may be gone for some reason, but no way to know for sure until we fully check it. Remove the main pack Negative for 20-30 mins. Then reconnect it and then plug your charger back in. This will reset the OBC and do a manual charge without any energy unit consideration.

As it is charging, you have to check each battery and the pack. We need to know 10ths. for every reading. After it cuts off, wait no less than 12 hours and then take the pack and each individual battery voltage readings again. If you do not do it as I stated, we will not be able to determine the true issue.

[Newt21]

The meter doesn’t do 10ths.

The readings are:
58
9/9/8/9/10/9

[NoleFan4Ever]

I assume those are while it is charging. You need another set no less than 12 hours after it completes. And you need to get another meter. It is a must to know 10ths (even 100ths in some cases) when dealing with these voltages.

Example w/your meter: 7.6=8, 7.6=8, 7.6=8, 7.6=8, 7.6=8, 7.6=8. Your meter will say 48v - Reality is 45.6v!

Harbor Freight or any tool store will have a $10 one and that will go to where you need it.

[Newt21]

Replaced 2 of the batteries and that seems to have taken care of the issue, cart charged and ran properly. Thanks for the help!

[Newt21]

Here we go again...

I'm not sure if it's the batteries or the meter at this point (the one on the golf cart). Last night I took these readings from the batteries: 8.9/8.7/8.5/8.5/8.6/8.5 and the total pack was 52.3 but the meter on the cart itself read 45.5 and had 5 of the 10 bars lit up.

I hooked it up to the charger, it clicked on and I did the same measurements while the charger was on: 10.3/9.9/9.8/9.2/10/9.7 and the whole pack read 60, the meter on the cart was reading 54 and change (don't remember exactly).

I waited over 12 hours and did the readings again this morning: 8.3/8.4/8.4/8.2/8.5/8.3 and total pack was 50.6. The meter on the cart read 40.8 and has only 1 bar out of 10 lit up.