PowerDrive 1 Breaker tripping

FZ0niner · 08-02-2018, 12:51 PM

I have a 2008 Club Car (new to me) and a PowerDrive 1 charger 17930 (came with the cart).

I've had intermittent issues with the charger and now its turned into a more consistent issue. Since I took delivery of the cart, I have only had what appears to be (1) successful charge with the charger.

What's happening is:

Plug PD1 into cart
Wait for clicking sound
Plug PD1 into the wall
PD1 clicks on, gauge jumps to 18-19
Appears to charge for 2-min gauge slowly dropping to 16
15amp breaker trips

What I've done so far to trouble shoot this:

Opened up PD1 to inspect
Heatsink, Relay and breaker all look fairly new (possibly replaced not long ago)
tested relay - pass
replaced 15am breaker
Cleaned batteries with baking soda / water
Disconnected batteries for over 10min to reset OBC
Tried charging in Tow mode
Inspected OBC and other components, no signs of burned wires

I tested each battery with a meter, and here are the results.

Battery #1 (Main Positive)
12.1v
Batt #2
12.1v
Batt #3
12.1v
Batt #4
12.3v

All batteries measured 48.2 volts

I'm running (4) 3-year old Trojan 12v batteries.

The cart is actually drive-able, but I'm afraid if I go riding to long I won't be able to recharge the batteries.

I've read a number of troubleshooting guides on here, not many for testing the AMP breaker issue.

Is there something else I should test?

Thanks,

ClubCarDSIQ · 08-02-2018, 01:14 PM

With my PD1 charger and 2002 DSIQ, I HAVE to plug the charger into AC power first before plugging in the cart. Maybe it is different with a 2008 cart, but the Powerdrive manual also states that the AC power needs to be plugged in before the DC output.
Don

Quote:

Originally Posted by FZ0niner

I have a 2008 Club Car (new to me) and a PowerDrive 1 charger 17930 (came with the cart).

I've had intermittent issues with the charger and now its turned into a more consistent issue. Since I took delivery of the cart, I have only had what appears to be (1) successful charge with the charger.

What's happening is:

Plug PD1 into cart
Wait for clicking sound
Plug PD1 into the wall
PD1 clicks on, gauge jumps to 18-19
Appears to charge for 2-min gauge slowly dropping to 16
15amp breaker trips

Thanks,

FZ0niner · 08-02-2018, 01:45 PM

Quote:

Originally Posted by ClubCarDSIQ

With my PD1 charger and 2002 DSIQ, I HAVE to plug the charger into AC power first before plugging in the cart. Maybe it is different with a 2008 cart, but the Powerdrive manual also states that the AC power needs to be plugged in before the DC output.
Don

Thank you for this, I just tried your recommendation and it tripped again after 2min. Regardless, I will continue this method going forward.

Fairtax4me · 08-02-2018, 02:03 PM

Does it have the long thin style breaker? What voltage ratings does it say on the sied of the breaker? I've had quite a few of those thin breakers fail and behave similarly to how you described. The larger squarish breakers with the round button I haven't ever had a failure. They're interchangable so either will physically fit in the PD1 charger, but I think the larger breakers are better.

There are several different voltage ratings for the small breakers, and I think they get accidentally mixed up because they look exactly the same. I had a few that said 36VDC on the side installed in 48V chargers (pretty sure they were aftermarket replacements). And those either failed or would trip repeatedly if the batteries were very low.
After replacing them with breakers that say 50VDC on the side, I havent had any problems.

FZ0niner · 08-02-2018, 02:38 PM

Quote:

Originally Posted by Fairtax4me

Does it have the long thin style breaker? What voltage ratings does it say on the sied of the breaker? I've had quite a few of those thin breakers fail and behave similarly to how you described. The larger squarish breakers with the round button I haven't ever had a failure. They're interchangable so either will physically fit in the PD1 charger, but I think the larger breakers are better.

There are several different voltage ratings for the small breakers, and I think they get accidentally mixed up because they look exactly the same. I had a few that said 36VDC on the side installed in 48V chargers (pretty sure they were aftermarket replacements). And those either failed or would trip repeatedly if the batteries were very low.
After replacing them with breakers that say 50VDC on the side, I havent had any problems.

Its a 15amp by Carling Technologies (125VAC 50VDC)

FZ0niner · 08-02-2018, 02:41 PM

So I was able to do some tests with a Neighbors Club Car at their house.

My neighbor has a Power Drive 3 that seemingly has zero issues.

I plugged my PD1 into their car, the gauge jumped to below 15 and ran for over 3 minutes without tripping.

I plugged the PD3 into my car and it did the same charged fine for over 3 min without tripping.

I plugged my PD1 back into my car at their house and it tripped again on time within 2 min.

Not sure where to go from here.

Fairtax4me · 08-02-2018, 03:16 PM

I would say the breaker is bad, but I'm no expert.

Your batteries may have a lower internal resistance than your neighbors batteries, which means they will charge at a higher amperage.
Higher charger current (output) requires a higher supply current (input) through the breaker. The breaker may be right on the fringe of being able to handle the load if the batteries don't need a full charge, but can't handle the higher current needed when the batteries are low.

FZ0niner · 08-02-2018, 03:16 PM

Is it possible my charger is not compatible with my year Club Car?

FZ0niner · 08-02-2018, 03:18 PM

Quote:

Originally Posted by Fairtax4me

I would say the breaker is bad, but I'm no expert.

Your batteries may have a lower internal resistance than your neighbors batteries, which means they will charge at a higher amperage.
Higher charger current (output) requires a higher supply current (input) through the breaker. The breaker may be right on the fringe of being able to handle the load if the batteries don't need a full charge, but can't handle the higher current needed when the batteries are low.

Breaker on the charger? I just replaced it with a new one.

FZ0niner · 08-02-2018, 03:21 PM

Quote:

Originally Posted by Fairtax4me

I would say the breaker is bad, but I'm no expert.

Your batteries may have a lower internal resistance than your neighbors batteries, which means they will charge at a higher amperage.
Higher charger current (output) requires a higher supply current (input) through the breaker. The breaker may be right on the fringe of being able to handle the load if the batteries don't need a full charge, but can't handle the higher current needed when the batteries are low.

My neighbors cart has (6) 8 volt batteries. Not Trojans. Maybe I should drive until the batteries low and try charging again?

08-02-2018, 12:51 PM	#1
FZ0niner Getting Wild Join Date: Jul 2018 Posts: 88	PowerDrive 1 Breaker tripping I have a 2008 Club Car (new to me) and a PowerDrive 1 charger 17930 (came with the cart). I've had intermittent issues with the charger and now its turned into a more consistent issue. Since I took delivery of the cart, I have only had what appears to be (1) successful charge with the charger. What's happening is: Plug PD1 into cart Wait for clicking sound Plug PD1 into the wall PD1 clicks on, gauge jumps to 18-19 Appears to charge for 2-min gauge slowly dropping to 16 15amp breaker trips What I've done so far to trouble shoot this: Opened up PD1 to inspect Heatsink, Relay and breaker all look fairly new (possibly replaced not long ago) tested relay - pass replaced 15am breaker Cleaned batteries with baking soda / water Disconnected batteries for over 10min to reset OBC Tried charging in Tow mode Inspected OBC and other components, no signs of burned wires I tested each battery with a meter, and here are the results. Battery #1 (Main Positive) 12.1v Batt #2 12.1v Batt #3 12.1v Batt #4 12.3v All batteries measured 48.2 volts I'm running (4) 3-year old Trojan 12v batteries. The cart is actually drive-able, but I'm afraid if I go riding to long I won't be able to recharge the batteries. I've read a number of troubleshooting guides on here, not many for testing the AMP breaker issue. Is there something else I should test? Thanks,
FZ0niner Getting Wild Join Date: Jul 2018 Posts: 88

08-02-2018, 02:41 PM	#6
FZ0niner Getting Wild Join Date: Jul 2018 Posts: 88	Re: PowerDrive 1 Breaker tripping So I was able to do some tests with a Neighbors Club Car at their house. My neighbor has a Power Drive 3 that seemingly has zero issues. I plugged my PD1 into their car, the gauge jumped to below 15 and ran for over 3 minutes without tripping. I plugged the PD3 into my car and it did the same charged fine for over 3 min without tripping. I plugged my PD1 back into my car at their house and it tripped again on time within 2 min. Not sure where to go from here.
FZ0niner Getting Wild Join Date: Jul 2018 Posts: 88

08-02-2018, 03:16 PM	#7
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: PowerDrive 1 Breaker tripping I would say the breaker is bad, but I'm no expert. Your batteries may have a lower internal resistance than your neighbors batteries, which means they will charge at a higher amperage. Higher charger current (output) requires a higher supply current (input) through the breaker. The breaker may be right on the fringe of being able to handle the load if the batteries don't need a full charge, but can't handle the higher current needed when the batteries are low.

08-02-2018, 03:16 PM	#8
FZ0niner Getting Wild Join Date: Jul 2018 Posts: 88	Re: PowerDrive 1 Breaker tripping Is it possible my charger is not compatible with my year Club Car?
FZ0niner Getting Wild Join Date: Jul 2018 Posts: 88

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08-02-2018, 02:03 PM	#4
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: PowerDrive 1 Breaker tripping Does it have the long thin style breaker? What voltage ratings does it say on the sied of the breaker? I've had quite a few of those thin breakers fail and behave similarly to how you described. The larger squarish breakers with the round button I haven't ever had a failure. They're interchangable so either will physically fit in the PD1 charger, but I think the larger breakers are better. There are several different voltage ratings for the small breakers, and I think they get accidentally mixed up because they look exactly the same. I had a few that said 36VDC on the side installed in 48V chargers (pretty sure they were aftermarket replacements). And those either failed or would trip repeatedly if the batteries were very low. After replacing them with breakers that say 50VDC on the side, I havent had any problems.