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Unread 06-15-2016, 04:22 PM   #1
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Default 2006 club car DS blew 2 chargers

I have a 2006 club car ds which I just purchased. I put 4 brand new 12 volt batteries in the car. After using the car for a while I plugged in the Charger and the charger clicked on after a few seconds and needle went to 15 amps and started charging, all good! When I came back next morning the charger was at zero which is what I thought was correct.The cart didn't fully charge because as I drove it about 1/4 mile it died on me. I trouble shot as much as I could and what I figured it was the relay in the charger but to be sure I borrowed a friends charger and plugged it in to my cart. The charger turned same as mine did and the next morning same thing happened it blew my friends charger. He took his apart and traced it that his relay was fried. I was a bit shocked to blow two chargers. I'm trying to figure out why the cart was blowing the Chargers? I checked all the cables, wires, etc. the last charge charged the battery to 48v before it blew. I started charging at 7:00, I doubled checked it at 12 and it was still charging. When I woke up charger was off and not working. when I put a meter to the 1st and 4th battery I got 48v.
So could the issue be the OBC? I' read that the on board charging system causes problems? Thanks in advance for your help. I used a power drive 2 club car charger model 22110 which came with the cart.
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Unread 06-15-2016, 04:50 PM   #2
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Default Re: 2006 club car DS blew 2 chargers

Double check that the batteries are wires in series correctly.
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Unread 06-15-2016, 10:55 PM   #3
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Default Re: 2006 club car DS blew 2 chargers

to BGW

I agree with mrgolf, double check your battery wiring. The batteries should be wired in series, + to -, and you should have one red wire going to the main + connection. This is the positive charging wire.
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Unread 06-16-2016, 07:15 AM   #4
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Default Re: 2006 club car DS blew 2 chargers

Ok so here is the thing... The relay is just a 48 VDC coil that pulls in to close a set of contacts and feed 120 VAC to the transformer. There is nothing on your cart that has the "ability" to burn through the relays on two different chargers. Are you sure it is the relay, and are you sure it is actually damaged?

Attached is pic. Is this the relay you speak of?
Attached Images
File Type: jpg Charger Jumper.jpg (188.4 KB, 0 views)
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Unread 06-16-2016, 08:49 AM   #5
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Default Re: 2006 club car DS blew 2 chargers

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Originally Posted by teecro View Post
Ok so here is the thing... The relay is just a 48 VDC coil that pulls in to close a set of contacts and feed 120 VAC to the transformer. There is nothing on your cart that has the "ability" to burn through the relays on two different chargers. Are you sure it is the relay, and are you sure it is actually damaged?

Attached is pic. Is this the relay you speak of?
This is great! I will check. I was told by an electrician that it was the relay he said when he jumped the wires on the relay the charger starting humming. I ordered the repair kit that has all the components you can change. I do know that both chargers after on my cart only click when you plug them in. So after returning my friends charger he went to charge his and it just clicked. The needle moved a hair forward then just went to 0. I will follow your instructions and let you know
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Unread 06-16-2016, 09:45 AM   #6
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Default Re: 2006 club car DS blew 2 chargers

There are a few things that don't make sense.

If the charger ran at 15 amps from 7:00PM until midnight (first post), You should have had a lot more than 48v, which is operationally dead for batteries.

Your last post indicates the issue was the contacts of the relay, about the only way that can happen is if the relay coil is being intermittently cycled while a load is present.

The OBC makes sure there is no load when it closes the relay, but if there is a bad connection on the sense wire, the relay could be cycling under load, which would destroy the contacts.

Pull good on the sense wire to make sure it is not about to come off and spray WD40 on the charger receptacle.
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Unread 06-16-2016, 11:14 AM   #7
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Default Re: 2006 club car DS blew 2 chargers

Quote:
Originally Posted by Sergio View Post
There are a few things that don't make sense.

If the charger ran at 15 amps from 7:00PM until midnight (first post), You should have had a lot more than 48v, which is operationally dead for batteries.

Your last post indicates the issue was the contacts of the relay, about the only way that can happen is if the relay coil is being intermittently cycled while a load is present.

The OBC makes sure there is no load when it closes the relay, but if there is a bad connection on the sense wire, the relay could be cycling under load, which would destroy the contacts.

Pull good on the sense wire to make sure it is not about to come off and spray WD40 on the charger receptacle.
First let me thank you for your time. I'm a novice first golf cart and I'M NOT A ELECTRIC OR MECHANICAL WIZ to say the least. Please educate me on the voltage first. If I put a meter on the 1st battery positive and the 4th battery negative what should the voltage read? Also the batteries are brand new this was the first charge. I have read that the batteries will not fully charge until the 10th charge, is that correct?
To clear up my first post I charged first with my charger it went right to 15amp and look to be charging fine. I left it without checking again until morning and it was now at zero. Being the first time ever charging the batteries I assumed all was good based on what I read how the charger works. I went to drive it and it died after a quarter mile. Lights were barely coming on so I assumed it after pushing it home it was dead. I plugged the charger in and it clicked needle moved a hair then back to zero. At the time I didn't have a voltage meter so I wasn't sure if it was fully charged and that's why the charger wasn't working or if the battery was to dead for the charger to pick up. So I charged each battery a bit with a car charger based on trouble shooting and then plugged in my charger. Same result click noise needle moved a hair then back to zero. So it was then recommended that I borrow a charger to trouble shoot if it was the cart or the charger. I plugged in my friends and soon as I plugged it in it clicked and the needle went up to charge mode. That was 7pm AT 12 PM it was still charging so I assumed all was good and it was just my charger that blew something. So I order the kit that has the relay, rectifier, etc. . The next morning my friends charger was at zero. I returned it to him and asked him to plug it in to see if it works just making sure. The answer was no something on his blew and wasn't working on his car. It was doing the same thing mine was, click moved a hair them back to zero So now I blew 2 chargers somehow. I was told from my friend that when he bypassed the relay it started humming but it wasn't actually plugged into his car. So I was just going by what he told me that it was the relay.
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Unread 06-16-2016, 11:24 AM   #8
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Default Re: 2006 club car DS blew 2 chargers

Quote:
Originally Posted by Chefcm View Post
First let me thank you for your time. I'm a novice first golf cart and I'M NOT A ELECTRIC OR MECHANICAL WIZ to say the least. Please educate me on the voltage first. If I put a meter on the 1st battery positive and the 4th battery negative what should the voltage read? Also the batteries are brand new this was the first charge. I have read that the batteries will not fully charge until the 10th charge, is that correct?
To clear up my first post I charged first with my charger it went right to 15amp and look to be charging fine. I left it without checking again until morning and it was now at zero. Being the first time ever charging the batteries I assumed all was good based on what I read how the charger works. I went to drive it and it died after a quarter mile. Lights were barely coming on so I assumed it after pushing it home it was dead. I plugged the charger in and it clicked needle moved a hair then back to zero. At the time I didn't have a voltage meter so I wasn't sure if it was fully charged and that's why the charger wasn't working or if the battery was to dead for the charger to pick up. So I charged each battery a bit with a car charger based on trouble shooting and then plugged in my charger. Same result click noise needle moved a hair then back to zero. So it was then recommended that I borrow a charger to trouble shoot if it was the cart or the charger. I plugged in my friends and soon as I plugged it in it clicked and the needle went up to charge mode. That was 7pm AT 12 PM it was still charging so I assumed all was good and it was just my charger that blew something. So I order the kit that has the relay, rectifier, etc. . The next morning my friends charger was at zero. I returned it to him and asked him to plug it in to see if it works just making sure. The answer was no something on his blew and wasn't working on his car. It was doing the same thing mine was, click moved a hair them back to zero So now I blew 2 chargers somehow. I was told from my friend that when he bypassed the relay it started humming but it wasn't actually plugged into his car. So I was just going by what he told me that it was the relay.
I forgot to ask where the sense wire is located?
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Unread 06-16-2016, 11:27 AM   #9
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Default Re: 2006 club car DS blew 2 chargers

Quote:
I put 4 brand new 12 volt batteries in the car
This is the key to your note...and your problems

1) What kind of batteries - golf cart batteries or something else?
2) If they were golf cart batteries, then when you installed them - you most likely did not wire them correctly - or you put the red wire from the charger socket to the wrong battery.

But without seeing a photo of you battery area - we can only guess.

The sense wire is located at the back of your charging socket on the cart.
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Unread 06-16-2016, 11:30 AM   #10
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Default Re: 2006 club car DS blew 2 chargers

There is a sticky on the top of this section that has the battery voltages, here is a link:
Everything to do with batteries!
Those are voltages taken after the cart has been off the charger, without driving, for at least 4 hours.

The "at least 10 charge cycle" thing has more to do with the reserve capacity of the batteries as the plates take a white to fully form and deliver the "run time".

You said, 12PM, I think You meant 12AM, otherwise the batteries had been charging for 17 hours at that point.

Since You charged the batteries individually, the OBC needs to be reset for it to work properly.

Disconnect the main negative cable from the battery pack and leave it disconnected so the OBC can reset.

Charge each battery individually with your car charger until each battery is fully charged.

Connect the main negative cable back to the pack negative battery post.

Measure the voltage on the charger receptacle at the cart and tell us what it is.
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