A dealer is converting 48V golf carts from lead-acid to a 51.2V LiFePO4 pack. The controllers were set up for lead-acid, and the technician wants to know what must be checked so that the cart does not cut out, lose regen or show a wrong state of charge.
Compare the controller’s voltage settings with the pack’s window. Redway’s 48V 100Ah golf cart pack is 51.2V nominal, with 58.4V maximum charge and a 40V discharge cut-off. Check the controller’s over-voltage limit (including regen), its low-voltage cutback, its current limit against the BMS rating, and the gauge. If any setting conflicts, change it with the controller maker’s tool, or choose a pack and BMS that fit.
The checks
- Upper limit. A full lithium pack plus regenerative braking can push voltage above 58V briefly. The controller’s over-voltage setting must allow this, and the BMS must accept the regen current; otherwise the BMS may cut off on a downhill. Our downhill shut-off article covers this case.
- Lower limit. The controller’s low-voltage cutback should act before the BMS cut-off of 40V, so the cart slows down gently instead of stopping.
- Current. The 200A-BMS version lists 100A continuous and 200A peak for 10 s; the 250A version lists 200A continuous and 250A peak; the 315A version lists 150A continuous and 315A peak for 30 s. The controller’s current limit should sit within the BMS rating for your duty.
- Gauge. A voltage-based lead-acid gauge reads a flat LiFePO4 curve badly. Use the pack’s SOC output where possible; Redway lists RS485, Bluetooth, app and LCD options.
- Charger. Replace the lead-acid charger with an approved lithium charger.
How to document it
Record controller model, firmware and settings before and after the change, and keep the record with the cart. Redway’s BMS and state-of-charge page and conversion page give more detail. Redway’s golf cart warranty is 3 years, and 5 years on the 48V 100Ah model.
Fleet roll-out
Convert one cart, run it for a week of normal use, and only then convert the rest with the same settings. Keep a copy of the settings file per controller model. If the fleet has more than one controller type, test each type separately.
Risk limits
Change controller settings only with the controller maker’s tool and guidance, and test on a closed course before returning the cart to service. Values above are from Redway product pages as of October 2026; confirm the specification for your pack.
Additional perspectives
Read and photograph the controller settings before you touch anything. If a cart behaves strangely after conversion, the before-and-after record shows what changed.
Redway Tech Editorial Team – Conversion technician perspective
Test a hard downhill stop with a full pack on one cart before converting the fleet. It is the most common case where controller and BMS limits collide.
Redway Tech Editorial Team – Controller specialist perspective
Offer the conversion as a package: pack, charger, gauge and controller check. Customers accept the price more easily than surprise extras after the first cut-out.
Redway Tech Editorial Team – Dealer owner perspective
Specifications are taken from Redway product pages as of October 2026. Where a figure isn’t published, this article says so. Confirm current specifications for your model with Redway before ordering. This article is general guidance, not a site-specific engineering assessment.
Related products
- 48V 100Ah LiFePO4 Lithium Golf Cart Battery OEM (BMS 200A)
- 48V 100Ah LiFePO4 Lithium Golf Cart Battery Manufacturer (BMS 250A)
- 48V 100Ah LiFePO4 Lithium Golf Cart Battery Factory (BMS 315A)
- 48V 100Ah Lithium Golf Cart Battery OEM Factory
- 48V 150Ah LiFePO4 Lithium Golf Cart Battery Factory
Related topics
- Golf Cart BMS, Monitoring & State of Charge
- Golf Cart Battery Installation, Wiring & Conversion
- Golf Cart Battery Safety & Protection
- Golf Cart Battery Charging & Chargers
- Golf Cart Battery Troubleshooting & Repair
- 48V Golf Cart Battery Systems
- Golf Cart Models & Battery Fitment
- Lithium vs Lead-Acid Golf Cart Batteries
- Golf Cart Battery Sizing, Voltage & Range
- Cable, Fuse & Breaker Sizing
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