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Unread 03-01-2015, 07:06 PM   #1
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Default 48V Charger Failure - I think

Cart is stock CC 1997 DS with Powerdrive charger. Recently I replaced the diode board, the relay, the breaker, and some little wire (that was in the kit) and all was well for about a month. Now suddenly the charger will not. I have already verified all cables and terminals are all good and clean, and that the DC connector is clean and well connected with a good fuse. I have the OBC bypassed and verify the charger relay activates. Batteries and battery cables are new and pack voltage is 49.6VDC with no battery below 8.0. I measure 59.6VDC coming off the transformer and all the way through to the battery pack. Problem is, there is no longer a transformer hum, no longer any reading on the ammeter, and apparently not much charging current. Charger fuse link is good. Is it possible that the transformer has gone south? Seems unusual. I do not have a spare charger or spare cart to cross-check with. What have I overlooked, and where would you all steer me to next? Thanks!
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Unread 03-01-2015, 08:58 PM   #2
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Default Re: 48V Charger Failure - I think

Can you still drive the cart?
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Unread 03-01-2015, 09:19 PM   #3
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Default Re: 48V Charger Failure - I think

Quote:
I measure 59.6VDC coming off the transformer and all the way through to the battery pack
Are You saying You measured 59.6v at the battery pack battery posts?

or did You measure to the charger receptacle on the cart?

If You measured at the charger receptacle, trying running a 10ga wire from the negative of the charger receptacle directly to the pack negative battery.
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Unread 03-01-2015, 09:20 PM   #4
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Default Re: 48V Charger Failure - I think

No, but that's another problem that I was planning to write in a different thread, so as not to co-mingle the two. Unless you believe they're related.
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Unread 03-01-2015, 09:21 PM   #5
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Default Re: 48V Charger Failure - I think

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Originally Posted by Sergio View Post
Are You saying You measured 59.6v at the battery pack battery posts?

or did You measure to the charger receptacle on the cart?

If You measured at the charger receptacle, trying running a 10ga wire from the negative of the charger receptacle directly to the pack negative battery.
I am able to measure 59.6 at teh charger receptacle and at the pack posts.
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Unread 03-01-2015, 09:22 PM   #6
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Default Re: 48V Charger Failure - I think

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Originally Posted by jjance View Post
Can you still drive the cart?
No, but that's another problem that I was planning to write in a different thread, so as not to co-mingle the two. Unless you believe they're related.
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Unread 03-01-2015, 09:33 PM   #7
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Default Re: 48V Charger Failure - I think

Quote:
Can you still drive the cart?
The reason I asked that is because you have strange voltage readings. I am thinking the batteries aren't connected and you are just reading the charger volts. What do your batteries read with the charger disconnected?
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Unread 03-01-2015, 09:42 PM   #8
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Default Re: 48V Charger Failure - I think

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Originally Posted by jjance View Post
The reason I asked that is because you have strange voltage readings. I am thinking the batteries aren't connected and you are just reading the charger volts. What do your batteries read with the charger disconnected?
With the charger disconnected I read 49.6 across the pack. If I power on the charger and jumper the relay, but do not connect it to the cart, I read 59.6 at the charger (which I assume to be the transformer secondary), where the red DC lead connects to the diode board and the black DC lead connectd to the ammeter/fuse terminal. If I connect charger to cart, I read this same 59.6 at the receptacle and at the pack. I never made this measurement when all was well (no reason to) so I cannot compare good to bad. No wires have been changed from the time all was well until now.
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Unread 03-01-2015, 09:58 PM   #9
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Default Re: 48V Charger Failure - I think

Do you by any chance have the sense wire jumpered to pack negative as well? If so, the voltage reading you are getting is through the charger relay coil.
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Unread 03-01-2015, 10:05 PM   #10
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Default Re: 48V Charger Failure - I think

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Originally Posted by Sergio View Post
Do you by any chance have the sense wire jumpered to pack negative as well? If so, the voltage reading you are getting is through the charger relay coil.
The charger relay is temp. bypassed (120V from fuse to transformer) since the OBC is currently untrustworthy.
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