Golf carts die early when power is wrong. Range drops. Heat builds. Trips end short. I fix this with simple checks on chemistry, current, charging, size, and proof.
Choose LiFePO4 by use, not hype. Match voltage and capacity to range, ensure BMS and peak current fit your controller, demand certifications and test data, size for safe install, and plan charging that protects cycle life.
A golfer called after an 18-hole rental died on hole 15. The pack was fine; the controller current was not. I swapped to a higher-rate pack and tuned limits. The cart finished with margin.
How long do LiFePO4 batteries last?
Life depends on depth of discharge1, temperature, and current. Good LiFePO4 packs reach 2,000–4,000 cycles to 80% capacity when charged to 80–90% and kept cool.
Expect roughly 2,000–4,000 cycles at 80% depth of discharge, moderate C-rates, and 10–35 °C. Partial charges, gentle discharge, and good thermal paths extend life. Heat, deep cycles, and fast charging shorten life.
Cycle life vs. conditions
| Condition | Typical result | What I do |
|---|---|---|
| 80% DoD, 25 °C, ≤0.5C charge | 3,000–4,000 cycles | Limit max charge to ~90%; avoid heat |
| 100% DoD, 35–40 °C | 1,500–2,500 cycles | Increase cooling; reduce DoD on hot days |
| Cold use (<0 °C) | Voltage sag; slower charge acceptance2 | Pre-warm; charge only above 0 °C |
| Fast charge (>1C) | Extra fade; BMS stress | Keep to 0.5–0.7C for fleet longevity |
Calendar life matters too
Cells age even when idle. I store at 40–60% state of charge, in a cool room, and cycle quarterly to keep the pack healthy.
Simple life extender list
- Stop at 90–95% SOC for daily use.
- Size capacity so routine DoD is 60–80%.
- Keep the pack and charger out of sun and engine heat.
- Balance charge monthly if the BMS needs it.
What other factors should you check when choosing a LiFePO4 battery?
Buying a pack is not only capacity. I check voltage, continuous and peak current, BMS limits3, charger profile, size, weight, IP rating4, and compliance. Then I check warranty and support.
Match system voltage and controller current first. Confirm BMS protections, low-temp charge cut-offs, and communication. Ensure the case fits and cools. Demand IEC/UN test reports. Pair the right charger. Check service terms.
Must-check specs for carts
| Item | Why it matters | My target/notes |
|---|---|---|
| Nominal voltage | Controller compatibility | 48 V or 51.2 V common; confirm limits |
| Continuous/peak current | Hills and starts | Peak ≥ 10 s rating; steady ≥ controller max |
| Capacity (Ah/Wh) | Range and payload | Size to finish 18–36 holes with reserve |
| BMS protections | Safety and uptime | OVP/UVP/OCP/OTP; pre-charge; HVIL if swappable |
| Low-temp charge cut-off | Cell safety in winter | No charging below 0 °C without heating |
| Case + IP rating | Dust, splash, wash-downs | IP54–IP67 based on environment |
| Size and weight | Tray fit and balance | Check drawings; keep CG low |
| Certifications | Compliance and shipping | IEC 62619, UN 38.3, CE; UL options for US |
| Charger match | Life and turnaround | CC/CV profile; 0.5–0.7C for fleets |
| Service & warranty | Real support | Clear RMA flow; local stock of spares |
Data that helps fleets
I prefer packs with CAN/CANopen data: SOC, SOH, cycle count5, temperature map, and event logs. This makes maintenance simple and predictable.
A quick personal checklist
I test hill climbs at full payload, measure peak current, log temps near noon, and then approve the BOM. I share the plots with the customer.
How do you tell you need a new battery?
Batteries age slowly, then fail fast. I watch runtime, voltage sag6, and charge acceptance2.
You likely need a replacement when range drops over 20%, voltage sags under load, or the BMS logs repeated protection events. A swollen case, hot charging, or long balance times are red flags.
Symptoms and likely causes
| Symptom | Likely cause | What I check/do |
|---|---|---|
| Range fell by >20% | Capacity fade | Full capacity test at 0.2C |
| Big voltage sag6 on hills | High resistance | Cell IR trend; busbar/connection check |
| Sudden BMS cut-offs | Over-current or undervoltage | Controller peak; BMS logs; settings |
| Pack hot when charging | High internal resistance | Reduce charge rate; inspect cells |
| Long time to balance | Cell drift | Balance settings; cell health |
Simple home test flow
- Fully charge with the correct charger.
- Drive a known route with typical payload.
- Log start SOC, end SOC, distance, temps, and peak current.
- If results are poor, run a 0.2C discharge test to 100% DoD under supervision.
Safety first
If you see swelling, smell electrolyte, or feel abnormal heat, stop using the pack and contact support.
Which brand offers good LiFePO4 batteries?
Great brands publish data, pass tests, and ship quickly. I look for cycle-life curves, real certifications, matching chargers, and US/EU stock. Then I compare service SLAs7.
RoyPow, RELiON, and Allied are established in carts. Junda Battery builds custom LiFePO4 packs with IEC/UN reports and modular trays. Pick by support, telemetry, and fit, not only price.
Brand snapshot (what I compare)
| Brand / option | Strengths | Fit notes |
|---|---|---|
| RoyPow | Turnkey kits; wide dealer network | Fast swap options for fleets |
| RELiON | Strong spec sheets; marine/cycle heritage | Good telemetry8 options |
| Allied | Drop-in sizes for legacy carts | Simple installs |
| Junda Battery | Custom voltage/capacity; IEC 62619 + UN 38.3; CAN data; local stock (US/EU/CA) | Co-design, matched chargers, fleet dashboards |
How I choose for a fleet
- I define range with 20% reserve in summer heat.
- I test hills at payload and record peaks.
- I pick the pack that meets peaks with thermal margin and has parts nearby.
A short story about service
A coastal course lost carts after storms delayed imports. We staged US stock and labeled spares by tray. The fleet ran through the season with zero downtime.
Conclusion
Match specs to the course, protect cycle life, demand proof, and keep service close.
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Learn about depth of discharge and its impact on battery lifespan and performance. ↩
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Learn about charge acceptance and its significance in battery charging efficiency. ↩ ↩
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Understanding BMS limits is essential for ensuring battery safety and efficiency. ↩
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Learn how IP ratings indicate battery durability and protection against environmental factors. ↩
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Understanding cycle count helps in assessing battery health and performance. ↩
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Explore the causes of voltage sag to better understand battery performance issues. ↩ ↩
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Understanding service SLAs can help you choose a reliable battery provider. ↩
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Discover how telemetry can enhance battery monitoring and maintenance. ↩
