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How should a golf fleet charge lithium carts overnight on a shared circuit?

48V 100Ah LiFePO4 Golf Cart Battery (S51105) 51.2v 100ah lithium (S51105L)

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Redway Battery Editorial Team

Talk / Battery Q&A

Buyer question

A club moved 30 carts to lithium. When all chargers start at 7 pm the barn breakers trip, and staff are moving plugs around by hand.

Main answerRedway Battery Editorial Team

Main answer

Direct answer: Add up the input current of the chargers on each circuit and keep it within what the circuit is rated to carry continuously; charging for hours counts as a continuous load under the US electrical code. If the total is too high, stagger start times, split chargers across circuits, or have an electrician add capacity. Lithium packs charged at their standard current usually finish well within one night, which makes staggering practical.

Battery side. The 48V 100Ah page lists a standard charge current of 22A with about 5 hours to full and 58.4V maximum. The 48V 150Ah lists 30A, about 5 hours, 54.75V maximum. The 48V 50Ah lists 22A and about 2.5 hours. Our arithmetic: 22A at about 58V is roughly 1.3 kW on the DC side; the charger draws more from the wall because of its own losses.

Circuit side. Read the input current on each charger’s nameplate (do not estimate it from the battery side). Multiply by the number of chargers on the circuit. NFPA 70 (NEC) treats a load expected to run three hours or more as continuous and requires branch circuits and overcurrent devices to be sized for 125% of continuous load, which in practice means loading a circuit to no more than 80% of its rating. Your local code and electrician have the final word.

Staggering. If carts need about 5 hours and you have 10 or more hours overnight, two groups can charge one after the other on the same circuit. Use the chargers’ delay start if they have one, or timers rated for the charger load; avoid manual plug-swapping late at night. Carts that came back with more charge can go in the second group.

Charger settings. Each charger must be set for its pack (58.4V and 54.75V packs need different settings, see how to read charger settings for the principle). Do not use lead-acid equalisation modes.

Inspection. Check cords, plugs and outlets weekly for heat marks, cracked insulation or loose contacts; a warm plug is a warning sign. Keep chargers ventilated and off the floor where water collects. Record breaker trips with the time and which chargers were running. For fleet buying questions, see questions before a fleet order.

Procurement perspective

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↳ Replying to Redway Battery Editorial Team

Compare the cost of extra circuits with the cost of timers and a staggered schedule before buying more chargers. An electrician’s load calculation is a small cost next to either.

Selection/Engineering perspective

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↳ Replying to Procurement perspective

Use nameplate input current, the number of chargers per circuit and the 80% continuous rule to check each circuit. Charging time per group comes from the pack’s standard charge current.

Maintenance perspective

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↳ Replying to Selection/Engineering perspective

Inspect cords, plugs and outlets weekly, keep a breaker-trip log, and check charger status lights each morning to catch carts that did not charge.

Add up the input current of the chargers on each circuit and keep it within what the circuit is rated to carry continuously; charging for hours counts as a continuous load under the US electrical code. If the total is too high, stagger start times, split chargers across circuits, or have an electrician add capacity. Lithium packs charged at their standard current usually finish well within one night, which makes staggering practical.

Verify before ordering: Charger models are not specified on Redway pages; use the nameplate data of your chargers and have circuits checked by a licensed electrician under local code.

Sources checked: NFPA 70 (NFPA).

Editorial Q&A for battery selection and operations. Product figures cited from Redway product pages.

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