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Unread 06-07-2014, 10:14 AM   #1
Not Yet Wild
Club Car
 
Join Date: Jan 2013
Location: Deland, Florida
Posts: 24
Default Battery Charger Not Working

Got hit with lightning last weekend. Charger quit working. Troubleshooting showed the Heatsink with Diodes to have failed. Install a new Heatsink, circuit breaker and relay (bought a kit). Connected to the cart and nothing happened. Following the manual disconnect the dc, plug in Ac no hum, no click, no voltage across dc pins. checks OK

Disconnect AC connect DC to cart hear a click. check ok

Check transformer 113 primary voltage. check ok

Bypass relay. charger works, but kicks off and back on every 15 to 20 seconds.

Disconnect the other two wires connected to the relay and it stops kicking off and on. But the amp meter drops a couple of amps and immediately rises back up every 15 to 20 seconds. Just a flutter.

Any idea what is going on? Could it be the voltage suppressor? following the test procedure it tested OK.

Any help would be appreciated.
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Unread 06-07-2014, 12:18 PM   #2
Dazed & Confused
 
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Join Date: Nov 2011
Location: Z-HELLS FL
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Default Re: Battery Charger Not Working

it would help us to know the brand of charger and the volts ... also the model of cart
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Unread 06-07-2014, 12:45 PM   #3
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Default Re: Battery Charger Not Working

2002 DS 48 volts series motor. Lester power drive charger
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Unread 06-07-2014, 12:50 PM   #4
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Default Re: Battery Charger Not Working

Lightning could have done more damage to the circuitry. I have even seen it destroy the power transformer in a stereo system.
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Unread 06-07-2014, 01:21 PM   #5
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Default Re: Battery Charger Not Working

yep lightin is a *itch
try an OBC reset first.. then try your charger on another cart if possible
if no cart is unavailable then do OBC by pass

Resetting the Club Car On board computer - reset the OBC

To reset the OBC the following must be done in this order:

If no Tow/Run Switch then skip that step

• Key Switch to Off
• Forward/Reverse to Neutral
• Tow/Run Switch to Tow
• Disconnect the Battery NEGATIVE (–) wire from the Battery Minus terminal on the battery pack.
• Put the Tow/Run to Run
• Forward/Reverse Switch to Reverse
• Key Switch to On
• Press the throttle pedal down (hold it to the floor)

The reverse buzzer will sound (sometimes) and go off in about 30 seconds.
Leave the cart like that for 5 min to cause the OBC to reset.
After 5 min release the throttle pedal

To reconnect the OBC back into the system:
• Key Switch to Off
• Forward/Reverse Switch to Neutral
• Tow/Run switch to Tow
• Reconnect the Batt – wire to the battery minus
terminal on the battery pack.
• Tow/Run switch to Run
• Key Switch to ON

to by pass OCB
DO AT YOUR OWN RISK.…do not attempt unless you are familiar with electricity and electronics!
There are two ways to force the charger to turn on regardless of the OBC.

The first method is to disconnect the cart’s gray wire at the fuse near the charger receptacle. Then using a jumper wire, connect the receptacle side of the fused connector to the cart’s negative battery terminal. This will energize the charger’s 48V relay. If the charger doesn’t come on, it could be bad connections, wiring or charger relay.

The second method is to open the charger and remove the 120V wires from the relay and jump these together. This totally bypasses the relay and the OBC wire.


(If charger comes on but the charger ammeter shows 0 amps, check the fuse at the charging receptacle under the clear plastic cover.)

Both of these methods should both be temporary measures for troubleshooting, or as an emergency method of charging the batteries when they have been discharged so far that the OBC will not charge them.

The OBC provides the optimum method of charging the cart’s batteries. If the OBC is bad, it should be replaced
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Unread 06-14-2014, 07:16 PM   #6
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Default Re: Battery Charger Not Working

I did some more trouble shooting today.

If I by pass the relay in the charger exactly as crash test described the charger works, but kicks off and back on every 15 to 20 seconds.

If I disconnect the one or both of the two wires connected to the relay and it stops kicking off and on. But the amp meter drops a couple of amps and immediately rises back up every 15 to 20 seconds. Just a flutter.

If I leave the charger wired properly and do the OCB by pass as crash test described the charger works but the amp meter drops a couple of amps and immediately rises back up every 15 to 20 seconds. Just a flutter. Same problem as bypassing the relay.

I think I have two problems. One the OBC is stopping the charger from kicking on. I can make it work two different ways.

When jumping the charger relay the OBC is still in the circuit and causing the on and off of the charger. When the other wires are disconnected the OBC is no longer in the circuit and something in the charger is causing the flutter.

When bypassing the OCB I still get the flutter. therefore it is not the OBC but something in the charger.

Anyone have any thoughts about what is wrong in the charger? This is a Powerdrive.
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Unread 07-21-2014, 09:43 PM   #7
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Default Re: Battery Charger Not Working

Did you ever get this fixed? If you did, what was the problem?
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