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Unread 04-08-2019, 07:50 AM   #11
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Default Re: DPI charger for 48 volt

A


Checked the diode. The top to terminals show a reading when checked in bought directions.The bottom terminals show no reading at all. Am I doing it right. If so then the diode is bad????.
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Unread 04-08-2019, 07:52 AM   #12
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Default Re: DPI charger for 48 volt

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A

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Unread 04-08-2019, 08:58 AM   #13
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Default Re: DPI charger for 48 volt

That charger should work fine with your cart. The Powerdrive charger that comes with the cart has no electronics inside either except for a small circuit board on the relay if its a PD3.

That charger wont be the best at charging the batteries, but it will work well enough. If you do go with a smart charger, you will not be able to use that DPI on that cart, as it will require the OBC to be present and working. Using a smart charger will require you to bypass the OBC. Putting the money into a smart charger would be your best option IMO.
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Unread 04-08-2019, 09:50 AM   #14
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Default Re: DPI charger for 48 volt

Thanks Fairtax. This is just a charger I had laying around. I thought I would check in to repairing it. I have a Power Drive 2 that came with the cart that I am in the process of building that works. I donít plan on using it on my cart. Just thought I would try to get it working so I my learn more about them. I agree with you on the smart charger. With a little more money than a OBC it is well worth it.


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Unread 04-08-2019, 10:37 AM   #15
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Default Re: DPI charger for 48 volt

If you want to try and fix it order you one of these from Amazon. For $3.55 you can't go wrong.

https://smile.amazon.com/TOOGOO-KBPC...gateway&sr=8-5
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Unread 04-08-2019, 12:34 PM   #16
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Default Re: DPI charger for 48 volt

More than likely it has either a poor connection at one of the wire terminals or a bad relay.

The rectifier may not be good, but you should still hear a click and the transformer should start humming when the charger is plugged into the cart.

With it UNplugged from the wall AC power, Plug the DC cord into the Cart.
Listen and feel for the relay to click. If it does not Check for pack voltage reaching the relay.
One of the two wires on the top of the relay is pack voltage and it should have that black wire from the transformer spliced to it.
The other wire should have continuity to Pack Negative if the OBC is telling the relay to turn on.
Check for poor connections or corrosion at the terminals at the relay.
Check for bad connections in those wire nuts also. Those really should be crimped on terminals, but it looks like someone replaced the charge cord at some point and just used what they had laying around to connect the wires.

If you have pack voltage on one pin, and continuity to pack negative on the other pin at the relay. The relay is bad.

The next step would be to either bypass the AC side of the relay, or remove the relay and test it individually.

To bypass the AC side you can either make a jumper with spade terminals, Or connect the transformer supply wire straight to the circuit breaker. Remove the short wire that runs from the breaker to the relay, and remove the large black wire that goes to the transformer from the relay and plug it to the breaker. Now if you plug in the AC cord you should hear the transformer hum, even if the charger is not plugged into the cart.

Unplug it from AC power, plug the charge cord into the cart, and then plug back into AC power and the transformer should come on immediately and the ammeter should jump up and show that it is charging.
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Unread 04-08-2019, 01:03 PM   #17
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Default Re: DPI charger for 48 volt

Thanks Fairtax, I will try that .Will post outcome
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Unread 04-08-2019, 02:38 PM   #18
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Default Re: DPI charger for 48 volt

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Thanks Fairtax, I will try that .Will post outcome


With ac cord unplugged an dc cord plugged to cart there was no click from relay. Tested voltage on red wire on top of relay pack voltage. Tested other wire ( white) to pack negative and it had continuity. Looks like the relay is bad.


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Unread 04-08-2019, 04:33 PM   #19
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Default Re: DPI charger for 48 volt

Also forgot to write in the thread above, you can check the relay coil resistance. Not totally sure what it should be but if it reads Open, Infinite resistance, or dead 0 ohms, then its bad.

Bypassing the relay should get the transformer to turn on so you can see if it charges correctly before replacing the relay.
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Unread 04-08-2019, 05:03 PM   #20
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Default Re: DPI charger for 48 volt

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Originally Posted by Fairtax4me View Post
Also forgot to write in the thread above, you can check the relay coil resistance. Not totally sure what it should be but if it reads Open, Infinite resistance, or dead 0 ohms, then its bad.

Bypassing the relay should get the transformer to turn on so you can see if it charges correctly before replacing the relay.
Relay coil 0 ohms. so that is bad. Will bypass transformer to check that before ordering parts. Thanks for all your help.
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