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Unread 01-31-2018, 05:56 PM   #11
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

It may be that your reported numbers were at different times, but with a pack voltage of 48.8v at rest, that meter should be close to the middle of the "green" zone.

I am assuming you purchased a 48v coil relay, if in doubt just post a link to the relay you bought.

The OBC should have powered the relay within seconds of the DC plug being plugged to the cart, so this is not normal.

You may want to clean the plug by disconnecting the charger from the AC plug, spray some WD40 in each of the cart receptacle sockets and work the DC plug IN/OUT several times to clean any oxidation.

The blown fuse in the yellow "sense" wire is likely an indication the charger relay suppression diode has failed, you need to test the diode or just buy a new diode before the OBC is damaged (1N4004 through 1N4007).
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Unread 01-31-2018, 06:23 PM   #12
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Ok, charging done. Last measurement I was able to get while the batteries were charging was 55.4v while charging at ~5a. Now that it has stopped (couldn’t have stopped more than 10 min ago), I am getting 50.1v across the pack. I just realized that the cart still has the #6 gauge wires on it. should have noticed this when I started messing with this thing again, but I didn’t. Not sure if it effects the charging, but I thought I’d mention it.
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Unread 01-31-2018, 06:24 PM   #13
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Club Car 1018286-01, 48V Relay PowerDrive Chargers, 95+ https://www.amazon.com/dp/B00BLP1Y0S?ref=yo_pop_ma_swf

This is the relay I bought.
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Unread 02-01-2018, 02:07 AM   #14
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Subbed for reasons of curiosity lol
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Unread 02-01-2018, 06:33 AM   #15
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Also, fwiw the battery charge light came back on 30 min after I noticed the charge cycle completed. At that time the pack was reading 49.9v. I am going to replace the heatsink/diodes on the charger and see what happens.
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Unread 02-01-2018, 07:22 AM   #16
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

At 50.1v your pack was only 85% charged so You do have a problem.

That relay you posted is the correct relay for a Powerdrive "charger".

I would not put any more money into that Powerdrive "power supply" until You determine if the problem is the OBC.

If the OBC is bad, it will be more economical to buy a "smart charger" than replace/fix the OBC/Powerdrive combo.

The gauge of your cables is not a problem, but if they are the original 21 year old cables, there is a good possibility you have bad/corroded connections.

You need to make sure the charger relay "clicks" within a few seconds of plugging the DC cord into the cart.

Do not attach your voltmeter to the relay coil wires since a "low impedance" voltmeter would appear as a relay to the OBC and it could give you false results.

Set your meter to continuity, unplug the charger AC cord from the wall and place the multimeter probes on the 2 blades of the AC plug.

Plug the DC cord to the cart receptacle, you should "hear" the relay click and the multimeter should show continuity.

If the relay "clicks" but the meter does not show continuity, Your issue is on the AC side of the Powerdrive.

If the relay does not "click" or has an extended delay before clicking, You are better off just buying a new smart charger since a blown fuse in the yellow holder usually means the FET inside the OBC that turns the charger relay on was likely damaged.
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Unread 02-01-2018, 09:39 AM   #17
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Thanks for taking the time to help me out. I'll try this when I get home. If the OBC check fail, I am guessing that this is what I need to pick up: https://www.amazon.com/Lester-Summit.../dp/B00LABPHXS ? Or, in your opinion, is there a better option?
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Unread 02-01-2018, 09:56 AM   #18
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Those steps are for the Onboard charger, is that what you have?

Check with our site sponsors, there are a few options available:

http://www.RevolutionGolfCars.com

http://www.Cartsunlimited.net
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Unread 02-01-2018, 09:58 AM   #19
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Quote:
Originally Posted by Sergio View Post
Those steps are for the Onboard charger, is that what you have?
After I looked at the images, I realized the instructions were not for my charger and removed the link. My bad.
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Unread 02-06-2018, 04:59 PM   #20
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Default Re: Battery light on a 1996 48v (sn-A9649) is staying on

Quote:
Originally Posted by Sergio View Post
At 50.1v your pack was only 85% charged so You do have a problem.

That relay you posted is the correct relay for a Powerdrive "charger".

I would not put any more money into that Powerdrive "power supply" until You determine if the problem is the OBC.

If the OBC is bad, it will be more economical to buy a "smart charger" than replace/fix the OBC/Powerdrive combo.

The gauge of your cables is not a problem, but if they are the original 21 year old cables, there is a good possibility you have bad/corroded connections.

You need to make sure the charger relay "clicks" within a few seconds of plugging the DC cord into the cart.

Do not attach your voltmeter to the relay coil wires since a "low impedance" voltmeter would appear as a relay to the OBC and it could give you false results.

Set your meter to continuity, unplug the charger AC cord from the wall and place the multimeter probes on the 2 blades of the AC plug.

Plug the DC cord to the cart receptacle, you should "hear" the relay click and the multimeter should show continuity.

If the relay "clicks" but the meter does not show continuity, Your issue is on the AC side of the Powerdrive.

If the relay does not "click" or has an extended delay before clicking, You are better off just buying a new smart charger since a blown fuse in the yellow holder usually means the FET inside the OBC that turns the charger relay on was likely damaged.


Hey, I’ve been out of town; but now I’m back at it. I tested for continuity to the AC plug like you instructed. When I plugged in the charging cable, the relay tripped after 1-2 seconds and I had continuity at the plug. Because I was surprised that the relay tripped so quick, I unplugged the charging cable and plugged it back in a minute later....nothing. I found a video on YouTube describing how to check the heat sink on a similar charger. The guys said that if you have continuity across the two diodes in pic), that the diodes were bad; so I tried that. With nothing plugged in, I got continuity between the two diodes. Can I safely assume that I should replace the heatsink and cross my fingers that that is the issue?
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