Battery breakin or break in procedure procedures

[rhinoman]

I actually have the reducer running off a relay, switched by the ignition. I figure with kids climing on it when not in use, or someone walking by playing, it was better to make sure lights etc were all off when key=off.

What's the best way to determine when the pack should be considered 'full charge', and calibrate the voltmeter ?

I have one of the dashmount LCD meters coming this week... I'm guessing that will be more accurate and tuned than a $10 meter from Canadian Tire.

[OLD MEC]

Im glad you went with a relay, I used an additional 48 volt solenoid ( with diode ) to switch my 12 volt battery with. I purchased a HD unit so that if my factory solenoid went bad I could use it as replacement.
Im very old fashioned in that I use a temperature correcting hydrometer to do most of my testing. If you go this route the batterys should be fully charged at 1.277 taken after allowing 1 hour from charge to settle down. Then you can set your voltmeter for accuracy.
I have always stayed with a simple analog type meter ( gas guage type ) as the lights flashing back and forth while changing speeds bothers me, its all in personal taste. The newer digital meters are great but have the same problem of changing numbers so fast that to me the only time any type is good is at rest, before starting out?

[rhinoman]

Yes, the drop to 'orange' is unnerving. I'm looking forward to the digital meter to let me assess the cart before driving to be sure I know where I stand.

Time to go pick up the proper hydrometer. I hate not having something calibrated :)

[OLD MEC]

Im with you on calibrating equipment. What good is a meter that isnt accurate?

[rhinoman]

Just checking in on this thread. I have a friend that repairs electric forklifts etc, and he's going to lend me his calibrated meter. This should allow me to set my meter appropriately. The gas-gauge meter doesn't allow for calibration though....

[bg481]

Originally Posted by shadowman

this is how i exp;laine it to customers and it has never failed me........brand new batteries are approx70 to 75% so once they are installed ( correctly ) the 1st 10 to 12 complete charge/discharge cycles are as follows plug charger in and leave it alone until charger shuts off by itself than drive cart to about 50% battery life and plug back in and repeat charge cycle.......very important you leave it charge until its completly done and this is what you want to do 10 to 12 times ......by the 12th time you,ll notice a differtence in powr/speed and runtime.........i have never had a customer say they havn,t........ther most common comment i get is wow its like a different cart..........thats the break inperiod pretty simple wouldn,t you say..........while doing this keep an eye on water level as i have sen it take 16 hours or better the 1st few times as they break in you,ll notice charge time gets less also........................after that the 2nd most important thig is maintaining the batteries........very critical you get into a ruintine of spending a whole 20 minutes a few times a month to keep things in good/clean and tight condition to get a lot more time out of your batteries......................................... ..............

Tom,
Great post,I got a 96 CC 48v,It only has a low battery lite indicator,How do I tell that the battery's are run down to 50%,I got new Trojans and dont want to ruin them.. Thanks for the help..
Alan

[scottyb]

You can use a voltmeter and this chart

[bg481]

Scottyb,
Thanks Alot,Alan

[mememe]

Originally Posted by scottyb

You can use a voltmeter and this chart

Excellent!

[scottyb]

BUMP
I copied some of Tom's Post and editied some of my battery preaching into a flyer for new battery owners... They forget what I tell them before I get to the end of their drive The battery State of Charge Chart is in this thread. Use that and any cheap meter is better than no meter, to implement this plan

NEW BATTERY BREAK-IN PROCEDURE:
Following proper break-in procedure can increase the strength and the useful life span of your new batteries. New batteries are initially about 75% of their full strength. The following procedure will insure they reach their full potential.
The 1st 10 to 20 complete charge/discharge cycles are critical to insure they reach 100%. New batteries should be charged before use and thereafter as follows:
Plug the charger in and leave it alone until charger shuts off by itself. Then drive to discharge the batteries to 75% battery pack capacity (see chart) Plug the cart back in and repeat the charge cycle.......It is very important you let it charge until it is completely done. Repeat this for the first 10 - 20 cycles......by the 12th cycle you will notice a difference in power, speed, and run-time.........I have never had a customer say they have not noticed the increase.
Most importantly, NEVER run the battery pack down below 50% of capacity throughout their entire life. Never leave the batteries in a state of discharge for extended periods of time. Recharge the pack once a week if the cart is sitting idle or in storage. And when in doubt, recharge it.
During the break-in procedure, keep an eye on the water levels (use distilled water only). I have seen it take 12 hours or better for the 1st few Charging times. These extended charge cycles may evaporate some of the distilled water.
As the batteries break in you will notice the charge time gets shorter. Eventually going from 12 to 5-6 hours per recharge.

ONCE A MONTH:
Routine maintenance is the 2nd most important thing to insure you get the most use out of your new battery pack. It is critical that you get into a routine of spending 10 - 15 minutes a month to keep the cable connections clean and check the water levels. Proper water level is critical. Dry batteries die quickly.
Keep the Distilled Water level up to the bottom of the fill hole sleeve or a half inch above the lead plates. Do not fill to the top.
Use a hard nylon brush to remove any visible corrosion. Carefully check that all of the cable connections are tight. Loose connections cause arching which will melt the soft lead terminals. Spray-on Battery Terminal Protector is available from the auto parts store and greatly reduces corrosive build up.
I hope this helps you get the most use possible out of your battery investment.