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Unread 06-07-2009, 07:18 PM   #1
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Default Charger Problem?

Howdy All!

I have a 2004 48V CC IQ. When I plug it in, the charger comes on and goes all the way over to 15 and then it cycles off after about 1 minute. It is a PowerWise charger. I checked the batteries and they are all between 8.23 and 8.26V and the full pack reads 49.6V. The batteries are all new Trojan T-875s. I put 2ga cables on it yesterday and that was when i noticed it. Any ideas?

Thanks a lot for any help.
BAF
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Unread 06-07-2009, 07:27 PM   #2
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Default Re: Charger Problem?

Quote:
Originally Posted by blaynef13 View Post
Howdy All!

I have a 2004 48V CC IQ. When I plug it in, the charger comes on and goes all the way over to 15 and then it cycles off after about 1 minute. It is a PowerWise charger. I checked the batteries and they are all between 8.23 and 8.26V and the full pack reads 49.6V. The batteries are all new Trojan T-875s. I put 2ga cables on it yesterday and that was when i noticed it. Any ideas?

Thanks a lot for any help.
BAF
What about the OBC, did you change the wire going through it as well?, (very tight fit for a 2 gauge welding wire!) Did you not put one through the OBC? You must have that lead going in the right direction for the charger to turn on. My cart is an 06 and shows the Negative lead disconnected, and most likely, a different OBC but, basically the same scenario.
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Unread 06-07-2009, 07:36 PM   #3
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Default Re: Charger Problem?

Thanks, Scubabud. No, I didn't change that one. I only changed all of the ones on the batteries, controller, and motor. What should I do now?

Thanks,
BAF
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Unread 06-07-2009, 07:49 PM   #4
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Default Re: Charger Problem?

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Originally Posted by blaynef13 View Post
Thanks, Scubabud. No, I didn't change that one. I only changed all of the ones on the batteries, controller, and motor. What should I do now?

Thanks,
BAF
So the direction is exactly the way it was, with the main negative lead from the battery going through the OBC and back to the controller? I thought that would be it for sure since the charger is coming on it when it sensed your pack voltage. How about your DC connection, (round plug on cart,) as well as the male cord plugs, are they clean making a good connection? And I know that you must have checked your wiring but I would look once more and make sure it's like what the attached picture shows.

Since the only thing you did was change the battery cables you must look at those again as well as anything you might have changed or bumped/moved by accident. Also do you have a friend with a CC to test your charger with?
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Unread 06-07-2009, 07:58 PM   #5
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Default Re: Charger Problem?

I changed the wires one at a time to make sure I got them back on correctly. I don't know anyone else with a CC to check my charger but it was working fine until I did this. I figured i would screw something up when i went to working on it. I'll let it sit and fiddle with it some more tomorrow afternoon. I appreciate your help and let me know if you think of anything else.
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Unread 06-07-2009, 08:09 PM   #6
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Default Re: Charger Problem?

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Originally Posted by blaynef13 View Post
I changed the wires one at a time to make sure I got them back on correctly. I don't know anyone else with a CC to check my charger but it was working fine until I did this. I figured i would screw something up when i went to working on it. I'll let it sit and fiddle with it some more tomorrow afternoon. I appreciate your help and let me know if you think of anything else.
I hope someone else chimes in here as well...


Well maybe one more thing... what is the voltage at the female plug on your cart? Please use your voltmeter on it and let me know using only that for both positive and negative and then using the positive from that plug and the negative from your main (-) lead on the last battery.
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Unread 06-08-2009, 11:37 AM   #7
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Default Re: Charger Problem?

With Brand New Batteries perhaps the charger id telling you the pack is completely
charged.
Does cart run ?
If yes drive it for 15 minutes or so , then try charging again !
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Unread 06-08-2009, 12:08 PM   #8
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Default Re: Charger Problem?

They are about two months old. I rode it Saturday for a while and then plugged it in to charge. Got back out there and the charger was off so i figured it was completey charged. I rode for a little while (30 mins or so) and the light started blinking like the batteries were low. That is when i checked the voltage and then plugged it back in and noticed that the charger was cycling off. Does that help any?

Thanks,
BAF
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Unread 06-08-2009, 12:09 PM   #9
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Default Re: Charger Problem?

Oh, and to answer your question, the cart still runs fine.
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Unread 06-08-2009, 12:16 PM   #10
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Default Re: Charger Problem?

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Originally Posted by blaynef13 View Post
Oh, and to answer your question, the cart still runs fine.
What is the voltage at the female plug on your cart? Please use your voltmeter on it and let us know using only that for both positive and negative and then using the positive from that plug and the negative from your main (-) lead on the last battery. Can you do this?
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