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Unread 03-08-2014, 08:26 AM   #1
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Default Convert external charger to on-board

I have a pretty beaten up PowerDrive charge that came with an equally rough looking 2002 IQ. I have had an issue of when the wife takes the cart and puts it back she doesn't always seat the charge plug all of the way in and it does not charge. This was discovered the hard way. I recently had the flip bed and body of for some paint and I figured I would add the charger in the bagwell while all the rusted hardware was removed and stainless was going back on. I routed the wires and relocated the cart's receptacle in the battery area and I didn't even think of a safety lock that wouldn't allow the cart to drive while connected to the charger.

Long story short, I now have to plug in my 110v plug and flip the seat up and plug and unplug that firm/stiff 48v plug that I was hoping to never have to deal with again.

I know the 3 wires of my 48v plug are +, -, and communication for OBC, but is it some sort of redundant signal or can I cut the wire on the receptacle side and add a switch or relay to open or close that circuit when the key is on/off? I know how to wire relays but I don't know much about these chargers.

I searched onboard chargers and that just netted the real OEM ones. I looked but didn't seem anything else exactly as I was trying to do...Advice?





Once this is figured out I plan to add a 25-50' retractable extension cord inside the vehicle as I have plans to make it a little cooler looking and more simple/functional. I now have a spot at work I can plug in so the clean cord would be a plus.
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Unread 03-08-2014, 08:52 AM   #2
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Default Re: Convert external charger to on-board

. . . removed . . .
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Unread 03-08-2014, 09:02 AM   #3
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Default Re: Convert external charger to on-board

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Originally Posted by Stevegrmich View Post
. . . there are 3 wires in the DC output cord/plug of the charger . . . there are 3 wires/connections on the back of the DC input receptacle in the cart . . . why can't you just cut the plug off the charger cord, route it into the battery area from the bagwell area and wire it directly to the back of the cart's receptacle inside the battery area, maintaining the integrity of the sense lead and no other switch would need to be added?. . .
I'm trying to follow here, but if I cut the cord end and wire up as if there was no receptacle how would it be any different, just now not really reversible. The issue I have is that if all 3 wires are connected to the wires in the receptacle then the cart will not run.

The plus is in the battery area now, along with the receptacle that I removed from the body and it all now lays between the batteries.

I guess I'm not seeing what is different in this situation.
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Unread 03-08-2014, 09:08 AM   #4
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Default Re: Convert external charger to on-board

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Originally Posted by yetti96 View Post
I'm trying to follow here, but if I cut the cord end and wire up as if there was no receptacle how would it be any different, just now not really reversible. The issue I have is that if all 3 wires are connected to the wires in the receptacle then the cart will not run.

The plus is in the battery area now, along with the receptacle that I removed from the body and it all now lays between the batteries.

I guess I'm not seeing what is different in this situation.
. . . yup . . . got ahead of myself . . . you still need to "break" the sense lead when not charging the cart for interlock to allow cart to be driven . . . so your toggle switch inline on the sense lead should work . . .
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Unread 03-08-2014, 09:31 AM   #5
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Default Re: Convert external charger to on-board

An other thing to consider is that the standalone charger may not hold up well to the vibration, heat, and dirt exposure associated with on-board installation.

Might be better to teach the better half
1. how to seat the plug
2. wait to hear the charger come on or see the needle move
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Unread 03-08-2014, 09:39 AM   #6
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Default Re: Convert external charger to on-board

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Originally Posted by scottyb View Post
An other thing to consider is that the standalone charger may not hold up well to the vibration, heat, and dirt exposure associated with on-board installation.

Might be better to teach the better half
1. how to seat the plug
2. wait to hear the charger come on or see the needle move
Good point. I tried and it turned into her just not plugging it in because she doesn't want to do it wrong :) I smell laziness but that's not what we are here to talk about.

So Scotty, how can I better shield this charger from the elements? I like the idea of being able to charge places other than home as well as not have the charger in the way on the garage floor


Can the terminals be "lubed" up with an electrical friendly grease like dielectric grease and ease the insertion of the plug? I took the plug apart and the barrels of each wire receptacle have a wire that holds the tip together, this is good for a positive connection that doesn't fall out but that makes for the stiffer push.
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Unread 03-08-2014, 09:45 AM   #7
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Default Re: Convert external charger to on-board

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Originally Posted by yetti96 View Post
Good point. I tried and it turned into her just not plugging it in because she doesn't want to do it wrong :) I smell laziness but that's not what we are here to talk about.

So Scotty, how can I better shield this charger from the elements? I like the idea of being able to charge places other than home as well as not have the charger in the way on the garage floor


Can the terminals be "lubed" up with an electrical friendly grease like dielectric grease and ease the insertion of the plug? I took the plug apart and the barrels of each wire receptacle have a wire that holds the tip together, this is good for a positive connection that doesn't fall out but that makes for the stiffer push.
Did you marry my wife's twin?
Some synthetic grease will lube the connection but it will also attract and old dirt and debris which ultimately will hinder the contact or insertion of the plug.
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Unread 03-08-2014, 09:49 AM   #8
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Default Re: Convert external charger to on-board

. . . about once or twice a season I spray WD40 into the receptacle on the cart . . . plug goes in and out like crap through a goose . . .
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Unread 03-08-2014, 10:44 PM   #9
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Default Re: Convert external charger to on-board

Either spray some WD40 in the charger receptacle to make it work smoothly or put a toggle switch on the sense lead. These carts are designed not to run when the DC cord is plugged into the vehicle whether the AC cord is plugged in or not. Club Car On-Board chargers have an AC interrupt circuit board installed in them that will allow the cars to run with the DC Cord inserted. These boards are rather pricy. Simple solution would be the toggle switch.
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Unread 03-09-2014, 09:17 PM   #10
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Default Re: Convert external charger to on-board

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Originally Posted by TahoeDawgZ71 View Post
Either spray some WD40 in the charger receptacle to make it work smoothly or put a toggle switch on the sense lead. These carts are designed not to run when the DC cord is plugged into the vehicle whether the AC cord is plugged in or not. Club Car On-Board chargers have an AC interrupt circuit board installed in them that will allow the cars to run with the DC Cord inserted. These boards are rather pricy. Simple solution would be the toggle switch.
I'm thinking toggle for now and maybe a relay that opens the sense lead when the dash key turns on.

You can see below that the sense lead seems to just piggyback off of the ground.
Maybe I don't fully understand how this circuit works but I would think it would be a varried current or maybe signal (pulsed). Is it really that simple?

PS, the wd40 trick made it way better (used bike chain lube as it's all I could find).

Edit: Just kidding. The sense is the thinner, fused wire in the yellow holder right?




Last edited by yetti96; 03-09-2014 at 09:22 PM.. Reason: Looked again
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