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Let's dive into upgrading your Club Car golf cart from lead acid batteries to lithium. This is a popular upgrade for many golf cart owners these days and for good reason.
They’re lighter, which means your cart will be easier to maneuver and will have a better range since the motor doesn’t have to work as hard. They also have a much longer lifespan, sometimes up to 10 years, so while the initial investment is higher, you'll save money in the long run by not needing to replace them as often. Additionally, lithium batteries require significantly less maintenance compared to lead acid batteries, which need regular watering and equalization charges.
People are making the switch to lithium because of these benefits. They’re tired of the constant maintenance and shorter lifespan of lead acid batteries. Plus, lithium batteries charge faster and hold their charge longer, making them more convenient and reliable for those who use their carts frequently or for longer trips.
How do I upgrade my Club Car?
When upgrading, one common issue you might encounter is if your cart is equipped with an On Board Computer (OBC). The OBC, which came standard on most 48V Club Cars from around 1996 to 2014, manages the charging cycle of lead acid batteries. However, when you switch to lithium, the OBC often needs to be bypassed because it can't properly manage the new battery type. Without bypassing the OBC, you might face running issues.
For the best results, it's recommended to upgrade to a single 48V or 36V 105Ah lithium battery rather than using multiple individual 6V or 8V lithium batteries. This approach helps with better balancing which is important for longevity and efficiency of lithium batteries. When batteries are not properly balanced, certain cells may experience overdraw or overcharge, while others remain underdrawn or undercharged. This imbalance can result in reduced performance, shortened lifespan, and potential BMS lockout.
Two highly recommended brands for lithium batteries are Eco Battery and Trojan OnePack. These companies have proven themselves with high quality products and stellar customer support. Their batteries are backed by solid reputations and are designed to handle the demands of golf carts effectively.
Along with the new battery, you’ll need to upgrade your charger to one with a lithium charging algorithm. Lithium batteries require a different charging profile compared to lead acid batteries, and using the wrong charger can damage them. A Battery Management System (BMS) is also highly recommended. The BMS monitors the battery's health, verifying cells are balanced and protecting against overcharging, undercharging, and overheating. It's important to choose a battery that can handle up to 300 amps of draw for a reasonable amount of time to make sure your cart performs well without tripping the BMS. If the BMS trips, it shuts down the battery to prevent damage, which can leave you stranded or damage your cart’s electrical system.
Here's a list of components you’ll typically need for the upgrade:
In terms of time and labor, if you’re handy with tools and comfortable working with electrical systems, you can probably do the upgrade yourself in a weekend. However, if you’re not as confident, hiring a professional might be worth the investment. Professional installation could cost anywhere from $200 to $500, depending on the rates in your area and the specific requirements of your cart.
Will lithium give my 36v cart more speed?
If you're currently running a 36V setup and seeking more speed, switching to lithium alone won't significantly boost your speed, except for a slight improvement due to weight reduction and increased range. For a noticeable increase in speed, upgrading to a 48V system is your best bet. Most 36V golf cart motors can handle the increased voltage, providing a substantial performance boost. However, to make this upgrade, you'll need a 48V battery pack, a compatible charger, a new 48v solenoid, and possibly a heavy duty forward/reverse switch to handle the increased power. It's also wise to check your controller's compatibility with 48V for smooth operation.
How about resistor carts?
Resistor carts, which utilize a series of resistors to control speed and power as opposed to electronic solid state speed control, are not recommended for lithium battery upgrades. This is because the resistor system is inefficient, wasting a significant amount of energy as heat and not taking full advantage of lithium's benefits like efficiency and longevity. Additionally, resistor carts maintain a consistently high amp draw even at slower speeds, which often conflicts with the operating range of most lithium Battery Management Systems (BMS). Upgrading a resistor cart to a solid state system is a more complex and costly endeavor. It typically requires a MCOR throttle sensor, a new controller, and other necessary parts such as solenoids and wiring. Given these extensive modifications, it might be more cost effective and less hassle to sell your current cart and purchase one that already has a solid state setup. This approach not only saves money but also ensures you get a more reliable and modernized system right from the start.
Types of lithium batteries
Lithium ion (Li-ion) and Lithium Iron Phosphate (LiFePO4) are two common types of lithium based batteries, each with distinct characteristics and advantages.
Lithium-ion (Li-ion) batteries are widely used in consumer electronics, electric vehicles, and various other applications. They are known for their high energy density, which means they can store a lot of energy relative to their size and weight. This makes them ideal for applications where space and weight are critical factors. However, Li-ion batteries can be sensitive to temperature extremes, require sophisticated battery management systems (BMS) for safety, and have a shorter lifespan compared to LiFePO4 batteries.
Lithium Iron Phosphate (LiFePO4) batteries, on the other hand, are a subtype of lithium-ion batteries that use iron phosphate as the cathode material. They are known for their excellent thermal stability, safety, and long cycle life. LiFePO4 batteries are less prone to overheating and are more chemically stable, reducing the risk of thermal runaway (a condition where the battery overheats uncontrollably). They also tend to have a longer lifespan, often exceeding 2,000 charge cycles. However, LiFePO4 batteries typically have a lower energy density compared to traditional Li-ion batteries, meaning they are larger and heavier for the same energy capacity.
What about upgrading the charger?
You'll need to upgrade the charger to accommodate the specific charging needs of lithium chemistry, which differs significantly from lead acid batteries. Lithium batteries require a charging algorithm that includes phases like constant current and constant voltage, while lead acid batteries typically undergo three main stages: bulk charging, absorption, and float. In contrast, lithium batteries require a different approach: they begin with a constant current phase, where the charger delivers a set current until a certain voltage is reached. This is followed by a constant voltage phase, where the voltage is maintained while the current decreases, allowing a complete charge without overcharging. The danger lies in using a lead acid charger with lithium batteries, where the end stage charge rate could be too high, potentially leading to overheating and overcharging.
For post 2014 Club Car models without an On Board Computer (OBC) such as those with ERIC PowerWise chargers, you can potentially continue using your existing charger by updating it with a lithium algorithm if available. This update allows the charger to properly charge lithium batteries adjusting its cycle to match their specific requirements.
What potential issues arise when bypassing the original charging port?
Upon upgrading to lithium, you may need to bypass the original charging port to connect your new charger. A interlock is a safety feature found in some golf carts charger port that prevents the cart from operating. It helps prevent driving away with the charger still attached by sensing the charger plug. However, when bypassing the original charging port or modifying the charging system of the cart, the charger interlock may need to be bypassed (if equipped). This is because lithium chargers may not be compatible with the original interlock mechanism. If the original charging port is removed, it may shut down the cart. Bypassing the charger interlock involves modifying or disabling the circuit that prevents the cart from being disabled. It allows the cart to operate normally without the original charging port.
Accommodating headlights and accessories
For golf carts equipped with original lighting systems, Club Car typically wired a 16v to 12v voltage reducer to two 8 volt batteries or avoids using a voltage reducer and instead wires directly to a single 12 volt battery if the cart has a 4x12 volt battery setup. However, when switching to lithium batteries, it's best to remove and install a 48 volt to 12 volt reducer. Using a 48 volt to 12 volt reducer allows all accessories to receive a consistent and stable voltage.
Technical Support
Overall, upgrading to lithium batteries is a fantastic way to improve the performance, reliability, and convenience of your Club Car golf cart. I always recommend taking advantage of the technical support offered by trusted companies like Eco Battery and Trojan when purchasing new batteries. Their exceptional customer support systems are invaluable for troubleshooting, optimizing performance, and helping with a smooth transition, especially when upgrading to technologies like lithium batteries. While cheaper alternatives may seem tempting, they often lack warranties and reliable support, leaving you vulnerable to potential issues without proper backup. Our community is also here to assist you every step of the way, feel free to post in the Club Car Electric Forum if you need any guidance or have questions during your upgrade.
Offseason Storage
Storing lead acid batteries and lithium batteries for the off season requires different approaches due to their chemical makeup and care needs. Lead acid batteries need regular attention, they should be kept fully charged to prevent sulfation, where sulfate crystals form and reduce battery capacity. They also require proper ventilation and avoiding extreme temperatures to stay in good shape during storage. On the other hand, lithium batteries are easier to store because they typically have an on/off switch and a lower self discharge rate, meaning they can hold onto their charge longer without needing maintenance. It's best to store lithium batteries at around 50% charge in a room temperature, dry place to maintain their health over time. Unlike lead acid batteries, lithium batteries typically don't need regular checks or special charging routines, making them simpler to handle during periods of non use.
They’re lighter, which means your cart will be easier to maneuver and will have a better range since the motor doesn’t have to work as hard. They also have a much longer lifespan, sometimes up to 10 years, so while the initial investment is higher, you'll save money in the long run by not needing to replace them as often. Additionally, lithium batteries require significantly less maintenance compared to lead acid batteries, which need regular watering and equalization charges.
People are making the switch to lithium because of these benefits. They’re tired of the constant maintenance and shorter lifespan of lead acid batteries. Plus, lithium batteries charge faster and hold their charge longer, making them more convenient and reliable for those who use their carts frequently or for longer trips.
How do I upgrade my Club Car?
When upgrading, one common issue you might encounter is if your cart is equipped with an On Board Computer (OBC). The OBC, which came standard on most 48V Club Cars from around 1996 to 2014, manages the charging cycle of lead acid batteries. However, when you switch to lithium, the OBC often needs to be bypassed because it can't properly manage the new battery type. Without bypassing the OBC, you might face running issues.
For the best results, it's recommended to upgrade to a single 48V or 36V 105Ah lithium battery rather than using multiple individual 6V or 8V lithium batteries. This approach helps with better balancing which is important for longevity and efficiency of lithium batteries. When batteries are not properly balanced, certain cells may experience overdraw or overcharge, while others remain underdrawn or undercharged. This imbalance can result in reduced performance, shortened lifespan, and potential BMS lockout.
Two highly recommended brands for lithium batteries are Eco Battery and Trojan OnePack. These companies have proven themselves with high quality products and stellar customer support. Their batteries are backed by solid reputations and are designed to handle the demands of golf carts effectively.
Along with the new battery, you’ll need to upgrade your charger to one with a lithium charging algorithm. Lithium batteries require a different charging profile compared to lead acid batteries, and using the wrong charger can damage them. A Battery Management System (BMS) is also highly recommended. The BMS monitors the battery's health, verifying cells are balanced and protecting against overcharging, undercharging, and overheating. It's important to choose a battery that can handle up to 300 amps of draw for a reasonable amount of time to make sure your cart performs well without tripping the BMS. If the BMS trips, it shuts down the battery to prevent damage, which can leave you stranded or damage your cart’s electrical system.
Here's a list of components you’ll typically need for the upgrade:
- 48V 105Ah Lithium Battery: $1,500 - $2,500
- Lithium-Compatible Charger: $300 - $500
- BMS (included with most high-quality lithium batteries): Typically included
- OBC Bypass (if applicable)
- Charger Interlock Bypass (if applicable)
- Battery Mounting Hardware and Cables: $100 - $200
In terms of time and labor, if you’re handy with tools and comfortable working with electrical systems, you can probably do the upgrade yourself in a weekend. However, if you’re not as confident, hiring a professional might be worth the investment. Professional installation could cost anywhere from $200 to $500, depending on the rates in your area and the specific requirements of your cart.
Will lithium give my 36v cart more speed?
If you're currently running a 36V setup and seeking more speed, switching to lithium alone won't significantly boost your speed, except for a slight improvement due to weight reduction and increased range. For a noticeable increase in speed, upgrading to a 48V system is your best bet. Most 36V golf cart motors can handle the increased voltage, providing a substantial performance boost. However, to make this upgrade, you'll need a 48V battery pack, a compatible charger, a new 48v solenoid, and possibly a heavy duty forward/reverse switch to handle the increased power. It's also wise to check your controller's compatibility with 48V for smooth operation.
How about resistor carts?
Resistor carts, which utilize a series of resistors to control speed and power as opposed to electronic solid state speed control, are not recommended for lithium battery upgrades. This is because the resistor system is inefficient, wasting a significant amount of energy as heat and not taking full advantage of lithium's benefits like efficiency and longevity. Additionally, resistor carts maintain a consistently high amp draw even at slower speeds, which often conflicts with the operating range of most lithium Battery Management Systems (BMS). Upgrading a resistor cart to a solid state system is a more complex and costly endeavor. It typically requires a MCOR throttle sensor, a new controller, and other necessary parts such as solenoids and wiring. Given these extensive modifications, it might be more cost effective and less hassle to sell your current cart and purchase one that already has a solid state setup. This approach not only saves money but also ensures you get a more reliable and modernized system right from the start.
Types of lithium batteries
Lithium ion (Li-ion) and Lithium Iron Phosphate (LiFePO4) are two common types of lithium based batteries, each with distinct characteristics and advantages.
Lithium-ion (Li-ion) batteries are widely used in consumer electronics, electric vehicles, and various other applications. They are known for their high energy density, which means they can store a lot of energy relative to their size and weight. This makes them ideal for applications where space and weight are critical factors. However, Li-ion batteries can be sensitive to temperature extremes, require sophisticated battery management systems (BMS) for safety, and have a shorter lifespan compared to LiFePO4 batteries.
Lithium Iron Phosphate (LiFePO4) batteries, on the other hand, are a subtype of lithium-ion batteries that use iron phosphate as the cathode material. They are known for their excellent thermal stability, safety, and long cycle life. LiFePO4 batteries are less prone to overheating and are more chemically stable, reducing the risk of thermal runaway (a condition where the battery overheats uncontrollably). They also tend to have a longer lifespan, often exceeding 2,000 charge cycles. However, LiFePO4 batteries typically have a lower energy density compared to traditional Li-ion batteries, meaning they are larger and heavier for the same energy capacity.
What about upgrading the charger?
You'll need to upgrade the charger to accommodate the specific charging needs of lithium chemistry, which differs significantly from lead acid batteries. Lithium batteries require a charging algorithm that includes phases like constant current and constant voltage, while lead acid batteries typically undergo three main stages: bulk charging, absorption, and float. In contrast, lithium batteries require a different approach: they begin with a constant current phase, where the charger delivers a set current until a certain voltage is reached. This is followed by a constant voltage phase, where the voltage is maintained while the current decreases, allowing a complete charge without overcharging. The danger lies in using a lead acid charger with lithium batteries, where the end stage charge rate could be too high, potentially leading to overheating and overcharging.
For post 2014 Club Car models without an On Board Computer (OBC) such as those with ERIC PowerWise chargers, you can potentially continue using your existing charger by updating it with a lithium algorithm if available. This update allows the charger to properly charge lithium batteries adjusting its cycle to match their specific requirements.
What potential issues arise when bypassing the original charging port?
Upon upgrading to lithium, you may need to bypass the original charging port to connect your new charger. A interlock is a safety feature found in some golf carts charger port that prevents the cart from operating. It helps prevent driving away with the charger still attached by sensing the charger plug. However, when bypassing the original charging port or modifying the charging system of the cart, the charger interlock may need to be bypassed (if equipped). This is because lithium chargers may not be compatible with the original interlock mechanism. If the original charging port is removed, it may shut down the cart. Bypassing the charger interlock involves modifying or disabling the circuit that prevents the cart from being disabled. It allows the cart to operate normally without the original charging port.
Accommodating headlights and accessories
For golf carts equipped with original lighting systems, Club Car typically wired a 16v to 12v voltage reducer to two 8 volt batteries or avoids using a voltage reducer and instead wires directly to a single 12 volt battery if the cart has a 4x12 volt battery setup. However, when switching to lithium batteries, it's best to remove and install a 48 volt to 12 volt reducer. Using a 48 volt to 12 volt reducer allows all accessories to receive a consistent and stable voltage.
Technical Support
Overall, upgrading to lithium batteries is a fantastic way to improve the performance, reliability, and convenience of your Club Car golf cart. I always recommend taking advantage of the technical support offered by trusted companies like Eco Battery and Trojan when purchasing new batteries. Their exceptional customer support systems are invaluable for troubleshooting, optimizing performance, and helping with a smooth transition, especially when upgrading to technologies like lithium batteries. While cheaper alternatives may seem tempting, they often lack warranties and reliable support, leaving you vulnerable to potential issues without proper backup. Our community is also here to assist you every step of the way, feel free to post in the Club Car Electric Forum if you need any guidance or have questions during your upgrade.
Offseason Storage
Storing lead acid batteries and lithium batteries for the off season requires different approaches due to their chemical makeup and care needs. Lead acid batteries need regular attention, they should be kept fully charged to prevent sulfation, where sulfate crystals form and reduce battery capacity. They also require proper ventilation and avoiding extreme temperatures to stay in good shape during storage. On the other hand, lithium batteries are easier to store because they typically have an on/off switch and a lower self discharge rate, meaning they can hold onto their charge longer without needing maintenance. It's best to store lithium batteries at around 50% charge in a room temperature, dry place to maintain their health over time. Unlike lead acid batteries, lithium batteries typically don't need regular checks or special charging routines, making them simpler to handle during periods of non use.
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