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REDWAY BATTERY / KNOWLEDGE

Do you need a DC-DC converter when a lithium golf cart battery powers 12V accessories?

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 cart owner is fitting a Redway 48V lithium pack in a cart whose lights, horn and radio run at 12V. The old lead-acid set was wired in a way that nobody on the team remembers.

Main answerRedway Battery Editorial Team

Main answer

Direct answer: If the cart already has a 48V-input voltage reducer, you will usually keep it, after checking that its input range covers the new pack’s voltage window. If 12V accessories were tapped from one battery in the old set, a lithium pack has no such tap, so add a DC-DC converter. This depends on your cart’s wiring, so check its manual and confirm with Redway.

Why it comes up: a lead-acid set is several batteries in series, so some carts have accessories wired to just one of them. A lithium pack is one sealed unit with one positive and one negative terminal pair (the golf cart pages list M8 terminals), so there is no tap. Tapping part of a series string also loads that part more than the rest, which is why many carts use a dedicated reducer instead.

Find out what your cart has. Look for a voltage reducer or DC-DC converter between the pack and the 12V accessories in the wiring diagram. If one exists, check that its input range covers the lithium pack. Voltage windows differ between Redway packs: the 48V 100Ah pack lists 51.2V nominal, 58.4V maximum charge and a 40V cut-off, while the 48V 150Ah pack lists 48V nominal, 54.75V maximum charge and a 37.5V cut-off.

Size the converter by current. Add up the 12V accessories (lights, horn, radio, USB sockets, GPS) at their running amps, and choose a converter whose continuous rating exceeds the total with margin. Ask for its idle current, because a converter left connected to a parked cart draws a little from the pack all the time. Redway does not publish a converter specification or recommended part on these pages.

Protect and isolate it. Fuse the converter’s input close to the pack, size the wiring for the input current, and make sure the key switch or main disconnect cuts power to it. The BMS protects the pack at its cut-off voltage, but a converter that stays live can keep drawing until it does.

After installation, measure the 12V rail with accessories on, check that lights and horn work, and watch the pack’s state of charge overnight through its BMS app or display to confirm there is no unexpected drain. Confirm the converter choice with the cart maker’s manual and Redway engineering before you buy, because the pages do not cover it.

Procurement perspective

Reply

↳ Replying to Redway Battery Editorial Team

Put the converter in the upgrade bill of materials, not as a surprise later. Ask the supplier whether the cart’s existing reducer is acceptable and get that in writing.

Selection/Engineering perspective

Reply

↳ Replying to Procurement perspective

Check the converter’s input range against the pack’s cut-off and maximum charge voltages, and its continuous current against the accessory load. Fit a fuse at the input.

Maintenance perspective

Reply

↳ Replying to Selection/Engineering perspective

Test the 12V rail under load, then check overnight state-of-charge drift. If the pack drains faster than expected, look first at converter idle current and any accessory wired around the key switch.

If the cart already has a 48V-input voltage reducer, you will usually keep it, after checking that its input range covers the new pack’s voltage window. If 12V accessories were tapped from one battery in the old set, a lithium pack has no such tap, so add a DC-DC converter. This depends on your cart’s wiring, so check its manual and confirm with Redway.

Verify before ordering: Redway publishes no DC-DC converter specification; the answer depends on the cart’s wiring. Confirm with the cart maker and Redway.

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

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