The Melex 625 Transport Golf Cart typically requires 48V or 72V battery systems, with capacity ranging from 150Ah to 210Ah depending on desired range and load requirements. LiFePO4 (lithium iron phosphate) batteries are the optimal choice for their 2000+ cycle life, thermal stability, and compatibility with golf cart electrical architectures. OEM replacements often use modular 8V lead-acid blocks (6 in series for 48V), but lithium upgrades like 48V165Ah or 72V150Ah packs reduce weight by 40–60% while doubling usable energy density.
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What voltage does the Melex 625 require?
The standard Melex 625 operates on a 48V DC system, though upgraded models may use 72V configurations. Original setups stack six 8V lead-acid batteries, but lithium conversions consolidate this into single 48V LiFePO4 units. Always verify your cart’s controller voltage rating—48V systems charge to 54.6V (LiFePO4), while 72V packs reach 81–84V.
Battery voltage directly impacts motor performance and torque. A 48V lithium system delivers comparable power to traditional lead-acid but with 30% reduced voltage sag under load. For example, a 48V165Ah LiFePO4 pack provides 7.9kWh usable energy versus 5.3kWh in 225Ah lead-acid equivalents. Pro Tip: Use a voltmeter to confirm your cart’s existing system voltage before purchasing replacements. Never mix lithium and lead-acid batteries in series configurations.
How does battery capacity affect range?
Capacity (measured in Ah) determines how far the Melex 625 can travel per charge. A 150Ah lithium battery provides ~56km range in flat terrain—30% more than equivalent lead-acid due to deeper discharge capability (80% DoD vs 50% for lead-acid). Larger 210Ah packs extend this to 78km, ideal for commercial operations.
Range calculations require analyzing amp-hour draw: Melex 625 motors typically pull 50–80A during acceleration. At 80A draw, a 150Ah pack lasts 1.8 hours (150Ah ÷ 80A = 1.875h). With an average speed of 32km/h, that translates to 60km. Real-world factors like hill gradient reduce this by 15–25%. Pro Tip: Multiply nominal capacity by 0.85 for practical range estimates to account for terrain and payload variables.
| Capacity | Lead-Acid Range | LiFePO4 Range |
|---|---|---|
| 150Ah | 40km | 56–60km |
| 210Ah | 55km | 77–82km |
Why choose LiFePO4 over lead-acid?
LiFePO4 batteries offer 5x longer lifespan (2000+ cycles) and 50% weight reduction compared to lead-acid. A 48V150Ah lithium pack weighs ~54kg versus 135kg for lead-acid equivalents, improving cart maneuverability and reducing tire wear. Their flat discharge curve maintains 95% voltage stability until 10% SoC, preventing performance drops during use.
Charging efficiency is another key advantage—LiFePO4 accepts 1C rates (150A charge for 150Ah packs) versus 0.2C for lead-acid. This enables full recharges in 1.5 hours with compatible 50A chargers. A real-world example: Golf course operators report 40% operational cost reductions after switching to lithium, despite higher upfront costs. Practically speaking, the ROI period is typically 18–24 months through eliminated replacement and maintenance expenses.
What physical dimensions are compatible?
Melex 625 battery compartments require L78 x W34 x H45cm (approximate) for standard configurations. Most lithium replacements use customizable modular cells to fit original spaces. For instance, 3.2V100Ah prismatic LiFePO4 cells arranged in 16S (48V) occupy 10% less volume than lead-acid blocks while delivering higher energy density.
Custom mounting solutions address slight size variations. For example, Jiangsu-based suppliers offer drop-in LiFePO4 units with ±5mm tolerance adjustments. Pro Tip: Always provide your cart’s existing battery tray measurements and terminal positions to manufacturers. Aluminum enclosures with IP65 rating are recommended for outdoor operation resistance.
| Type | Dimensions (LxWxH) | Weight |
|---|---|---|
| Lead-Acid | 81x35x48cm | 135kg |
| LiFePO4 | 75x32x42cm | 52kg |
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FAQs
Yes, most drop-in LiFePO4 units maintain original terminal layouts. Verify polarity alignment and confirm charger compatibility—lithium requires CC-CV charging profiles, not lead-acid’s constant current.
How long do Melex 625 lithium batteries last?
Properly maintained LiFePO4 packs deliver 8–10 years of service versus 2–3 years for lead-acid. Store at 50% SoC during offseason and avoid full discharges below 10%.
